mazda rx8 nitros

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mazda rx8 nitros

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This catalog printed with recyclable soy ink.
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Printed on 100% recycled paper.
Mazda Motor Corporation
3-1 Shinchi, Fuchu-cho, Aki-gun, Hiroshima 730-8670 Japan
September 2003
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M A Z D A E N V I R O N M E N TA L R E P O R T 2 0 0 3
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Note from the Editors
Mazda Motor Corporation began releasing these annual Environmental Reports in
2001, disclosing a variety of environmental information and data.
Specific content has been selected in accordance with the Environmental Reporting
Guidelines (2000 edition) on Japan issued by the Ministry of the Environment, to
explain and illustrate our environmental protection activities throughout every
phase of our business from automobile production to sale and final disposal. Toward this end, we have included key results and activities implemented jointly with
our sales firms, part and materials suppliers and logistics companies. Activities of
selected sales firms and affiliates are also covered.
New sections have been added this year to introduce the environmental protection
technologies utilized in our new Mazda6 / Atenza and Mazda2 / Demio models, released last year, as well as the adoption of production technologies with low environmental impact.
We have also expanded our coverage of Vehicle safety and workplace safety and hygiene, to facilitate better understanding of Mazda corporate activity.
Scope of this Environmental Report
［Organizations covered］
Mazda Motor Corporation, its domestic (Japanese) Group companies, and selected
Postscript
overseas Group companies.
The Mazda Environmental Report 2003 covers primarily our corpor-
［Period covered］
ate performance in environmental issues during fiscal 2002. Infor-
In principle, the fiscal year from April 2002 to March 2003, but also including selected activities from fiscal 2003.
departments, and has been arranged for readability, based as far as
［Contact information］
possible on concrete data.
Global Communications Planning Department +81(82)282-5253 FAX +81(82)287-5225
ISO Office (Hiroshima Region) +81(82)565-0642 FAX +81(82)287-5173
Customer Consultation Office (toll-free)
0120-386-919
［Website］
URL http://www.mazda.com
［Major public information releases］
Annual environmental report
mation and data listed is based on reports from individual internal
Annual
Environmental data for each model
Website
Company prospectus
Every six months
Press releases
As required
The next Environmental Report is scheduled to be released in fall 2004.
We are continuing our environmental activities, including further investigation of environmental audits by third parties, and acquisition
of ISO14001 certification in the parts sector in summer 2003.
Issued by: PR Planning Department, Mazda Motor Corporation
(Information) TEL +81(82)286-5744
FAX +81(82)287-5225
Date: September 2003
Next edition scheduled for fall 2004
Call Center
Toll-free: 0120-386-919
Hours: Monday to Friday (excluding holidays), 9:00 to 19:00
This document can also be viewed on or downloaded from Mazda's
website in PDF format.
http://www.mazda.com
M A Z D A
2003
E N V I R O N M E N T A L
Table of Contents
R E P O R T
Message from the president ……………………………3
Corporate Outline ………………………………………4
Outline of activities during fiscal 2002
RX-8 and the challenge of environmental protection ……6
Demio and Atenza and the challenge of environmental protection……7
Recycling Activities and Reductions in Waste ……………8
Development Activities and Reduction in Logistics Materials……10
Corporate Vision …………………………………12
Mazda's Relationship with the Environment…14
Environmental Management
Environmental Principles
……………………………16
Plan for Environmental Activities, ……………17
Promotion
and Results of Activities for 2002
Organizations and Systems ……………………………18
Environmental Monitoring………………………………19
Environmental Risk Management ………………………20
Education, Enlightenment and Communication Activities……21
Environmental Accounting ………………………………22
Results of Activities in 2002 and Outstanding Issues for the Future
Research & Development………………………………24
Manufacturing …………………………………………26
Green Purchasing ………………………………………28
Logistics ………………………………………………29
Activities to Promote Vehicle Recycling …………………30
The challenges facing dealerships ……………………31
The Green Office ………………………………………31
Safety Issues ………………………………………32
Community Activity
The Mazda Community Services Committee……………34
The Mazda Foundation …………………………………35
Mazda's History of Environmental Activities……36
Site data
Site report: Hiroshima Area ……………………………38
Site report: Hofu Plant …………………………………40
Environmental Data
Environmental Data for New Models /
Redesigned Models (Passenger Cars)…………………42
1
2
Message from the president
The protection of the global environment is a key responsibility of Mazda Motor Corporation as its carries out its corporate activities. We have clearly stated our determination to
actively fulfill this responsibility within our corporate vision, and under the guiding policy
defined in the Mazda Global Environmental Charter we have been making a real contribution to environmental protection and the attainment of a recycling society.
In parallel with these efforts, we have also been building cooperative programs for environmental protection. Environmental issues affecting the automotive industry, such as
global warming and effective utilization of resources, are global issues, and resolving them
will require cooperation between corporations, groups and industries. Mazda is continuing
to extend and strengthen its environmental management system, and in fiscal 2002 a total
of 337 major suppliers, including automotive parts and materials, acquired ISO 14001 certification, joining the Mazda production companies already certified. By sharing knowledge
and technology with the Ford Motor Group we are achieving successes in a wide range of
projects.
Fiscal 2002 marked a new start for Mazda. We redefined our brand message as "ZoomZoom," indicating the feelings we experienced as children about vehicles, and expressing
the new value we offer our customers. The concept has been successfully embodied in the
new Atenza, Demio and RX-8 models. The Atenza, for example, is powered by the newlydeveloped MZR engine, while the Demio has been designated as an Ultra-Low Emissions
Vehicle (U-LEV) by the Japanese Ministry of Land, Infrastructure and Transport. The newly-developed RENESIS rotary engine in the RX-8 has earned it a rating as a Excellent-Low
Emissions Vehicle (E-LEV). All Demio models have already cleared the fuel efficiency standards scheduled to take effect in 2010, as have all but a few models of the Atenza. They
provide superior traveling performance and driving pleasure with a new dimension in environmental soundness.
These results were achieved as part of our environmental action plan calling for Mazda to
meet the Japanese 2010 fuel efficiency standards in all weight categories of passenger
cars by fiscal 2005, and for at least 90% of all passenger car's sales to be U-LEV by the
end of 2005. Already 17 types of 12 model families comply with the Japanese 2010 fuel
efficiency standards, and 10 types of nine model families have been designated U-LEV. We
have also achieved our goal, stated last year, of zero-landfill level emissions at all domestic production sites in fiscal 2002. Due to an increase of 12.7% in sales, total CO2 emissions rose 6.8% over those of the prior year, but CO2 emissions per JY10 billion in revenue dropped 5.2%, indicating significant improvements in energy utilization efficiency
and reductions in energy consumption.
This Environmental Report summarizes Mazda's environmental activities for fiscal 2002,
including improvements in recyclability of used automobiles, promotion of "clean production," aluminum bonding using frictional heat and other production technologies related to
reducing environmental impact, as well as environmental management activities implemented through a cooperative effort by sales companies, suppliers and logistics firms. It
is our hope that this report will help you understand Mazda's efforts in environmental protection. Environmental protection activities are closely interrelated to improvements in
productivity and cost reduction. Environmentally sound products will lead to improved
productivity, technological progress and reduced materials cost, resulting in the creation
of new value for our customers. In recognition of this, Mazda Motor Corporation will continue to fulfill its commitment to environmental objectives by all business sectors together.
President and CEO
Hisakazu Imaki
3
CREATE
［Corporate Outline］
Aiming for a balance between the
creation of new values and harmony
with our environment
Mazda's automobiles are manufactured in two domestic and 15 overseas plants, and are driven in over 150 countries worldwide. Mazda is committed to the creation of products that deliver new values for future generations, as well as to the realization of sustainable development within both society and our corporate activities. For this reason, we consider environmental protection activities to be at the heart of our business, and the Mazda Group works hard in order to continue to
produce results in this area.
■ No. of automobiles sold
Consolidated
Non-consolidated
■ Ordinary Income
Consolidated
Non-consolidated
(100 million yen)
500
(Thousand vehicles)
1200
407
1,017
1,013
1000
964
879
400
948
827
872
821
800
283
300
100
600
245
192
200
77
61
0
400
-100
-200
200
-300
1999
2000
2001
■ Net Sales
2002 (Fiscal year)
Consolidated
(100 million yen)
25,000
Non-consolidated
1999
−323
2000
2001
■ No. of employees
2002 (Fiscal year)
Consolidated
Non-consolidated
(No. of people)
50,000
23,645
43,818
21,615
20,949
20,158
39,601
40,000
20,000
15,000
−297
-400
0
15,376
14,661
13,227
13,646
37,824
36,184
30,000
23,549
20,705
10,000
20,000
5,000
10,000
0
19,290
0
1999
4
19,948
2000
2001
2002 (Fiscal year)
1999
2000
2001
2002 (Fiscal year)
HARMONY
Company Outline
●Company Name: Mazda Motor Corporation
●Established: 30th January 1920
●Representative: CEO and President Hisakazu Imaki
●Capital: 120.07805 billion yen (as of 31st March 2003)
●No. of employees: 19,120 (as of 31st March 2003)
●Major business lines: Manufacture and sale of passenger cars and commercial vehicles
●Head Office: 3-1 Shinchi, Fuchu-cho, Aki-gun, Hiroshima 730-8670 Japan
●Main business premises:
(Domestic) Head Office / Tokyo Head Office / Osaka Branch / Hofu Plant / Miyoshi Operations /
Mazda R & D Center (Yokohama) / Mazda Technical Service Center (Tokyo) /
Mazda Technical Service Center (Nagoya) / Mazda Technical Service Center (Osaka) /
Mazda Technical Service Center (Hiroshima) / Mazda Rotary Shin-Umeda
(Overseas) Beijing Office
●Domestic Manufacturing Bases: Head Office Plant / Miyoshi Plant / Hofu Plant
●Research and Development Bases
(Domestic) Head Office Research & Development / Mazda R & D Center (Yokohama)
(Overseas) MNAO (Mazda North American Operations) / MME (Mazda Motor Europe)
●Production quantities: 776,682 units (during FY 2002, non-consolidated)
●Turnover: 2,3645 billion yen (during FY 2002, consolidated)
●Units sold: 1.017 million units (during FY 2002, consolidated)
●Operating profits: 50.6 billion yen (during FY 2002, consolidated)
●Pre-tax profits: 40.7 billion yen (during FY 2002, consolidated)
●Profits for period: 24.1 billion yen (during FY 2002, consolidated)
Main subsidiaries and affiliates
■Domestic
subsidiaries
Auto Atelier Co., Mazda Autozam,Inc
Kurashiki Syntheic Chemical Industries Co.,
Toyo Eitech Co., Microtechno Co., Mazda Ace Co., Mazda E & T Co.,
Mazda Chuhan Co., Mazda Butsuryu Co., Mazda Car Rental Co., Malox Co.
■Domestic
affiliates
Keyrex Co., Nihon Climate Systems Co.,
Yoshiwa Industrial Co.
■Overseas
subsidiaries
Mazda Motor of America Inc. / Mazda Canada Inc. / Mazda Motors (Deutschland)
GmbH / Mazda Motors Europe GmbH / Mazda Motor Logistics Europe N.V. /
Mazda Motor de Portugal Lda. / Mazda Motors UK Ltd. / Mazda Suisse S.A. /
Mazda Australia Pty. Ltd. / Mazda Motors of New Zealand Ltd. /
~ia Colombiana Automotriz S.A. / Mazda Sales Thailand Co., Ltd. /
Compan
~a S.A. /
Mazda Motor Italia S.p.A. / Mazda Automobiles Espan
Mazda Automobiles France
■Overseas
affiliates
Auto Alliance International Inc. / Lenawee Stamping Corporation /
Auto Alliance (Thailand) Co., Ltd. / Mazda Austria GmbH
5
Mazda is pressing ahead in a comprehensive and planned way with environmental activities, covering everything from R & D
and product development issues such as increased fuel economy, reductions in exhaust emissions, the promotion of recycling and the development of clean energy vehicles, to the achievement of zero emissions from our plants and offices, along
with improvements and extensions to our Environmental Management System. Our activities during fiscal 2002 are outlined
below, with some examples of how they are being reflected in our products.
RX-8 and the challenge of environmental protection
■New-generation rotary
engine RENESIS
The RENESIS Combustion chamber
■Improved recyclability and use of recycled parts
In addition to the use of thermo plastics, which is easily recycled, on bumpers and car interior materials, polymeric parts have a material marking in order to facilitate separation and recycling when the car is dismantled. The engine under cover is made from recycled materials that were collected from
damaged bumper in the market.
The newly developed RENESIS rotary engine, which is featured in the RX-8, uses
a side exhaust system that achieves high
fuel efficiency as well as significantly
cleaner exhaust emissions.
The volume of pollutants contained in exhaust emissions from the engine has
been reduced to less than 1/10 of that of
conventional engines, with the result that
the Ministry of Land, Infrastructure and
Transport has accredited the RX-8 as an
Excellent-Low Emissions Vehicle (E-LEV).
■Increased use of aluminum for reduced weight
The use of aluminum as a material in manufacturing automobiles is an important
approach in facilitating body weight reduction, which offers improvements in fuel
efficiency as well as greater safety and motive capacity. The new model RX-8 uses
aluminum in its bonnet and rear doors, and has achieved a roughly 12kg weight
reduction over previous models. In addition to this, Mazda has developed a cutting-edge welding technology for aluminum, based upon frictional heat, which has
allowed significant reductions in energy use in our manufacturing processes.
New aluminum welding technology allows significant reductions in
energy use as well as higher fuel efficiency due to lower body weight
Thermo-plastic parts used for bumpers
and interiors, improving recyclability
Aluminum materials used in bonnet, rear doors, and other parts
(weight reduction effect: 6.6kg in bonnet, 5.3kg in rear doors)
Engine under cover made from recycled
damaged bumper material
Mazda RX-8
Newly developed RENESIS engine
●Achieves 10km / l (5MT) in 10-15 mode
●Accredited with E-LEV rating
FY 2002 Activities: Topic 1
The world's first aluminum joining technology to use frictional heat
Mazda developed the world's first aluminum joining technology based on frictional heat in February 2003. This technique offers an energy saving of 99% in comparison to conventional resistance welding methods. Conventional resistance welding uses a significant amount of electrical
power as it requires a large electric current to be applied momentarily to the aluminum materials.
It also requires the use of coolant water and pressurized air. Frictional welding involves the use
of pins above and below the welding spot. Pressure is applied to these pins, and they are turned
at the same time, resulting in frictional heat which softens and liquefies the aluminum and results
in spot fusion. This method requires no electrical current or cooling water, and allows a reduction in the equipment required for welding processes. Mazda was the first manufacturer in the
world to develop this frictional heat welding method for aluminum, which provides significant energy and other cost savings. The method has opened up various new possibilities for the use of
aluminum in automobiles, as well as offering a significant contribution to the protection of the
environment wherever aluminum is being used in manufacturing industries.
6
RX-8 rear door
Joining aluminum components together using low-voltage electric power.
Mazda RX-8
Mazda Demio
Mazda Atenza
Demio and Atenza and the challenge of environmental protection
■Newly developed MZR engine achieves
Ultra-Low Emissions Vehicle (U-LEV) rating
The Atenza, released in May 2002, and the new Demio, which went on the
market in August the same year, both feature the newly developed, all-aluminum block MZR engine (Atenza 2.0-liter /2.3-liter, Demio 1.3-liter /1.5-liter),
which offers a balance of excellent performance with high fuel efficiency, low
emissions, low noise, reduced weight, compact size and excellent durability.
Mazda has continued to work on this engine since its release to further improve the cleanness of its emissions, and in March 2003, all models of the
Demio, along with the Atenza front-wheel drive released in July 2003 were
certified with the Ultra-Low Emissions Vehicle (U-LEV) rating as a result of
the fact that their emissions of NOx and hydrocarbons had been reduced to
75% of the standards set. All Demio models, along with the Atenza FWD 2.0liter, have attained Japanese 2010 fuel efficiency standards, and meet Green
Tax requirement.
The Atenza MZR Engine
Reducing the burden on the environment
in our manufacturing processes
Our newly developed all-aluminum in-line, four-cylinder MZR engine has not
only been accredited with a U-LEV rating, but it is also produced in a manufacturing process where various measures are taken to reduce the burden on
the environment.
Semi-Dry Processing - practical application
Semi-dry processing has been implemented on the machine processing lines for MZR
1.3l and 1.5l engines, with the result that a 75% reduction has been achieved in the
quantity of electrical energy being used, along with an 80% reduction in the volume of
waste liquid requiring processing. The processing method is now being rolled out to
cover the machine processing of various other non-engine components. Our efforts
in this area were rewarded when Mazda received the Minister of Economy, Trade and
Industry Award at the National Energy Saving Excellence Awards in fiscal 2002.
Wet processing
Semi-dry processing
In addition to the example above, we also developed a manufacturing technique
that allows us to recycle used grindstones into a filter that removes the smells
of ammonia and other gases emitted from the casting process for engine parts.
This development in the area of 'energy savings in theoretical approaches to the
energy plant' was rewarded with the Energy Conservation Center, Japan, Director's Award at the National Energy Saving Excellence Awards in fiscal 2001.
Three-Layer Wet Paint System - practical application
Following the successful development of the Three-Layer Wet Paint system,
which allows primer, clear coat and topcoat to be all applied in one process, Mazda has been working on further developments in low-solvent paints and high-efficiency paint spraying applications, and has introduced all these techniques at its
Hofu No. 1 Plant. These measures have enabled Brightening materials
(mica flakes, aluminum flakes)
total reductions in energy use during the painting
process to reach 15% (calculated in CO2 emisClear
sions), along with a 45% reduction in use of volBase
atile organic compounds (VOCs) such as xylene
Mid-coat
Electroplating
and toluene. These techniques are scheduled to
Steel sheet
be rolled out gradually for use in other plants.
The con-rod, crankshaft and other main components of the MZR engine are manufactured without using lead.
Three-layer wet paint application using
newly developed application techniques
7
Mazda MPV
Recycling Activities and Reductions in Waste
■Promoting Bumper Recycling
Mazda has been collecting damaged plastic bumpers from dealerships, and reusing the plastic as material for automobile parts since 1992. At present, we grind
and melt down collected bumpers into pellets, without removing the paint and use the resulting material in splash shields and footrests for new cars. Since July
2002, we have been using recycled bumper material in new car bumpers. (Please see pages 30 and 31 for further details).
Gradual increase in collection quantity of damaged bumpers
The practice of collecting damaged bumpers from dealerships nationwide has become well-established since its introduction in 1999, and the quantity collected is
growing gradually. During fiscal 2002, we recovered a total of 40,358 bumpers (141
tons).
Recycled bumper / Bongo Friendee (rear bumper)
Waste materials are sorted carefully, including damaged bumpers, metals, plastics, or cans used to store
oil, for example. Each type of waste is processed appropriately for recycling.
Hiroshima Mazda, Itsukaichi Branch
Bongo Friendee
■ Components using recycled materials in major models
Model
Atenza
(sedan / sports / sports wagon)
Part using recycled materials
Footrest
Demio
Splash shield
RX-8
Engine undercover
Familia
Bumper reinforcement,
splash shield, footrest
(S-wagon / sedan)
■ Quantity of damaged bumpers collected
( Thousand
bumpers )
40,358
40
Premacy
Splash shield
30
Roadster
Undercover
Millennia
Splash shield,
seal board upper
Bongo Friendee
Undercover, rear bumper
20
10
0
1995
8
1996
1997
1998
1999
2000
2001
2002 (Fiscal year)
Achieving zero-landfill levels during fiscal 2002, a year earlier than expected.
In order to achieve zero-landfill levels, we implemented controls on waste, as well as
recycling and reusing everything possible from waste product emissions. This allowed us to achieve zero-landfill levels in all our manufacturing plants in December
2002. In addition to maintaining zero emissions in fiscal 2003, we intend to implement additional new controls on the production of waste and further improve our reuse and recycling ratios. (Please see page 26 for further details).
Mazda announced its intention to achieve zero-landfill levels in the Zero Emissions
Declaration during fiscal 2001. The objective was to achieve zero-landfill levels from
all domestic manufacturing plants (including output from development, offices and
technical areas) by the end of fiscal 2003. In fact, we achieved zero-landfill levels a
year ahead of schedule, at the end of fiscal 2002.
■ Trends in landfill processed waste product since 1990
■ Date at which zero-landfill levels were achieved in each manufacturing location
Index (%)
120
Manufacturing location
100
80
Date achieved
Head Office Plant
December 2002
Hofu Plant
April 2002
* Mazda defines 'Zero Emissions' as a level of directly landfilled waste product equivalent to 5%
or less of that output in 1990.
60
40
20
0
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
Fiscal year
Encouraging affiliated companies to implement similar strategies
Independent Environmental Efforts by Group Companies
Major companies in the Mazda Group are not only advancing their own environmental management
systems through ISO 14001 certification and other measures, but also implementing individual programs for their specific fields of endeavor, or using proprietary technologies. Kurashiki Synthetic
Chemical Industries Co., Ltd. is one of these firms. As a manufacturer specializing in design, development and manufacturing of automotive rubber products, Kurashiki Synthetic Chemical Industries
acquired ISO 14001 certification in December 2001. The firm began to commercialize recycling
technology much earlier, though: in 1997 the firm recycled the rubber chips generated in manufacturing as rubber blocks for architectural and exterior use. Today, this product line of recycled materials has grown to include colored paving tile, artificial turf, decorative steppingstones and car barrier posts. The firm is now expanding its line of "Universal Design" recycled products featuring not
only environmental soundness but also a safer, cushioning effect based on the natural resilience of
rubber.
From fiscal 2002 the firm began utilizing waste tires from other firms as raw material, and currently
recycles about 500 tons of waste rubber annually.
EcoTile resilient, water-permeable paving blocks
made of rubber chips decorate the entrance to
the Kurashiki Synthetic Chemical Industries New
Technology Development Center.
9
Mazda's Bongo Van, first vehicle in its class to be fitted with a clean diesel engine, and currently undergoing monitored testing.
Development Activities and Reduction in Logistics Materials
■Development of exhaust emissions reduction technology
for diesel engines, and the start of the first monitored
test run phase in small commercial vehicle segment
■Presentation of a diesel engine / electric
motor hybrid truck at the 2002 Tokyo Motor
Show
The European model of the Atenza, which was released in 2002, along
with some other cars, employ our MZR-CD engine, a newly developed
common-rail direct-injection diesel engine which utilizes a high-pressure
injection technology developed uniquely by Mazda to achieve complete
fuel combustion. Mazda has added to this engine a newly developed
ceramic diesel particulate filter (DPF), along with some improvements to
the engine control technology, and in May 2003 fitted the engine to its
small commercial vehicle, the 'Bongo Van'. The Van is now under monitored road testing with a view to the practical application of this technology, which is the first in its class. The engine and filter work together to
offer a 75% or more reduction in particulate matter (PM) in comparison
with existing Bongo diesel engines, along with a 25%-plus reduction in
NOx emissions. Mazda is currently engaged in collecting data regarding
the use of the engine in actual road driving and under various conditions,
in order to verify its applicability in practical use, with the aim of it being
compatible with the various NOx and PM standards coming into effect in
urban areas, as well as regulations regarding the use of diesel engines
around the metropolitan Tokyo. Furthermore, new models of the Bongo
Van should be compatible with the new short-term regulations coming
into effect in October 2003.
Mazda displayed a truck at the 36th Tokyo Motor Show, held at Makuhari
Messe Convention Center between 30th October and 3rd November 2002,
which featured the newly-developed MZR-CD common-rail direct-injection
diesel engine in combination with an electric motor. This Titan Dush
hybrid truck achieves both low emissions and excellent fuel economy,
and incorporates various environmentally friendly features, such as an
EGR (Exhaust Gas Recirculation) cooling system, an oxidation catalyst and
continuous reusable filters. The additional assistance of the motor gives a
further 50% additional fuel economy in comparison with a same-model
diesel-only truck, along with a 65% reduction in NOx and 85% reduction
in PM emissions. Mazda is committed to further research and development
work in the field of diesel engines, in order to reduce emissions even further.
The Titan Dash Clean Diesel Hybrid (prototype)
10
■Mazda Digital Innovations (MDI) - contributing to
recycling and improvements in product safety.
Mazda began its project known as Mazda Digital Innovations in 1996, with
the aim of bringing about a digital revolution in all its processes, from the
planning stage through to manufacturing. Our activities in this area have
led not only to reductions in development time and in investment, but also
to contributions to environmental protection. Our development and manufacturing divisions have achieved a system that allows design data and
other information to be shared between them to be done in a paperless
way, contributing to a reduction in resources required. A crash simulator
improves unit test precision, and together with virtual testing through cutting-edge computer simulation programs has enabled us to cut the number of actual vehicles used in collision safety testing and other purposes
by around 45%. Mazda intends to continue working at the forefront of
information technology, in order to make further progress in environmental protection and the improvement of passenger and pedestrian safety
through development and production system technologies.
Development period
The virtual factory, which simulates the manufacturing process
Reduced from typical 18 months to 14 months
No. of prototypes tested
Equipment introduced during
FY 2002 relating to MDI
Virtual test system
(FY 2002)
Reduced by around 45% (for RX-8)
9 test and prototyping systems, including a side crash simulator
20
See page 32 for product safety
A simulated collision safety test
Data relating to environmental activities.
As a result of our research and development activities during fiscal 2002 in order to reduce emissions and increase fuel efficiency, we shipped a total of 151, 281 cars during the year that met with standards
defined by the Green Purchasing Act. In our logistics activities, efforts to reduce pollution during fiscal 2002 gave the following results in regard to purchasing and reduction of materials used in distribution.
■ No. of vehicles shipped compatible with the Green Purchasing Act during fiscal 2002
Passenger cars
Commercial vehicles
Total
Standard / compact
Clean energy
vehicles
Micro
Standard / compact
Micro
Electric vehicles
0
0
0
0
Hybrid vehicles
0
0
0
0
0
0
CNG-powered vehicles
7
0
13
0
20
0
0
0
0
0
7,214
21,007
2,380
0
30,601
☆☆
69065
3,052
0
8,388
80,505
☆
38,295
496
1,277
0
40,068
ー
ー
87
ー
87
114,581
24,555
3,757
8,388
151,281
Methanol-powered vehicles
High fuel efficiency /
☆☆☆
low emissions
vehicles
(accredited)※
Diesel-alternative LPG vehicles※
Total
※Vehicles which meet the preliminary standards for fuel efficiency
under the Energy Conservation Law, and for low emissions
under the Guidelines for Low-Emission Vehicle approval system.
☆☆☆ (Ultra-low emissions)
: 75% reduction from the
2000 emissions standard
☆☆ (Excellent-low emissions) : 50% reduction from the
☆ (Good-low emissions)
: 25% reduction from the
Continuing to Reduce Packing Material Use
We have already achieved considerable reductions in packaging materials
(also see page 29).
Transport pallet made with recycled
plastic
■ Reductions in the use of packaging / wrapping materials (wood and cardboard reductions)
Standard for 1999
Distribution
area
Retail
distribution
Details
Results for
2000
Results for
2001
Detail
Results for
2002
Returnable
2000
2001
Reused
2002
2000
2001
Reduced
2002
2000
2001
2002
KD component transportation
566
1,558
2,243
68
242
446
6
278
360
492
1,038
1,437
Shipping of parts to customers
279
808
1,023
105
523
675
59
128
137
115
157
211
Total
845
2,366
3,266
11
Corporate Vision
Since the definition of our Management Philosophy in 1984, and in line with the principles outlined therein, we have focused
on reform, while striving to produce new values for our customers. Based on this Philosophy, we defined our Corporate Vision in December 1999, which comprised a 'Vision' (corporate objectives) along with a statement of 'Mission' (roles and responsibilities) and 'Values' (the values Mazda seeks to produce). We are working towards a car society that has character
and innovation as well as being clean and safe, and these principles are helping express the ways in which Mazda and Mazda's employees understand their roles and responsibilities as they press towards the achievement of these aims.
Management Philosophy
To create new values, and bring enjoyment to people.
Corporate Vision
To create new value, excite and delight our customers
through the best automotive products and services.
With passion, pride, and speed, we actively communicate
with our customers to deliver insightful automotive
products and services that exceed their expectations.
We value integrity, customer focus, creativity,
efficient and nimble actions and respect highly
motivated people and team spirit. We positively
support environmental matters, safety and society.
Guided by these values, we provide superior
rewards to all people associated with Mazda.
12
Corporate Vision
2003 Environmental Report
Customer Satisfaction and Product areas
● Creating attractive products based on the concept of Mazda's
Worldwide Brand Positioning
［Mazda Brand Personality］
・Stylish
・Insightful
・Spirited
［Mazda Brand Products］
・Distinctive Design
・Exceptional Functionality
・Responsive Handling and Performance
Our branding message has been expressed, in a summary of the concepts
outlined above, as 'Zoom-Zoom' - a phrase which reminds us of the excitement
we felt as children when experiencing movement.
●Quality system organization
●TPM (Total Productive Maintenance) activities, etc.
Environmental and social action
●Definition of an environmental charter and promotion system that deals
with environmental issues
●Development of clean energies
●Reductions in CO2 emissions to contribute to the prevention of global warming
●Reduction of direct landfill waste from plants
●Introduction of new manufacturing technologies that are kind to both people
and the environment
●Efficient reuse and recycling of materials
●Promotion of 'Idling Stop' - encouraging trucks to switch off engines when parked
●Development of safety technology
●Fitting of safety equipment
●Promotion of widespread implementation and understanding of safety factors
●The establishment and operation of the Mazda Foundation
●Mazda Good Communication activities (international cultural exchanges)
●The Mazda Hospital
●Community activities etc.
13
Mazda's Relationship with the Environment
Mazda is committed to the reduction of environmental loading in all aspects of its work. In addition to this,
we aim to contribute to environmental protection through offering our customers products using environmentally friendly technologies. The diagram below show's Mazda's relationship with the environment.
We have illustrated our relationship with the environment in the processes involved in manufacturing our
products, as well as our administrative flow, from left to right on this diagram, while inputs of resources such
as electricity, and outputs of waste product and CO2 are shown in a top to bottom flow. Data regarding our
collection and reuse of damaged bumpers, which has been in effect since 1992, is also shown.
Electricity
Fuel
(crude oil / natural gas / coal)
IN
IN
■Mazda EMS (Environmental Management System) Promotion
Plants
Offices
Parts
materials
P.26・27
●Promoting reductions in use of resources
and energy in manufacturing
●Promoting clean manufacturing
●Management of chemical substances
●Recycling of by-products and waste product
emitted from plants
(Head Office / branch offices / local offices)
Research &
development
P.16∼23
P.24・25
●Improvement of fuel efficiency
●Reductions in emissions gas ●Reductions in noise
●Development of clean energy cars etc.
Purchasing
P.28
●Progress in ISO14001 attainment by our suppliers
●Purchasing environmentally friendly parts, materials,
equipment etc.
MDI
Offices
P.31
P.11
●Promotion of green offices
Quantity of resources and raw materials invested
Item
Energy (crude oil equivalent)
2.78×105
Water
41,150
Raw materials
Steel, aluminum, etc.
Paper
14
Amount
/year
/day
4.07×107 A4 sheets/year
Mazda Digital
Innovations
OUT
OUT
Waste product
CO2 emissions
Mazda's Relationship with the Environment
Water
IN
Recycled parts
Collection of damaged
bumpers through dealerships
No. of bumpers collected
during fiscal 2002: 40,358
Logistics
Dealerships
P.30・31
OUT
●Exhaust gas
reductions
●Noise, etc.
P.24・25
Usage
P.29
●Reductions in CO2 emissions through
efficient distribution
●Reductions in, and recycling of
packaging and wrapping materials
●Damaged bumpers collected for recycling
●Notification / education of customers
●Promotion of compliance with environment-related laws and environmental improvements
Customers
End-of-life
vehicles etc.
Mazda is implementing digital reforms in all processes, from the planning of new models to the
manufacturing stages. This has allowed a significant shortening of the development process, along
with a reduction in the environmental load created.
Automobile Recycling Act
OUT
P.30
Other gas emissions
Quantities produced
Item
Amount
Direct landfill
4.90×103
/year
Wastewater
8.97×106
/year
Exhaust gases
1.34×106
CO2
3.60×105
/hour
/year
15
Environmental Principles
Mazda established its Environmental Principles and Environmental Guidelines in 1992, and these
make up what has come to be known as the Mazda Global Environmental Charter, or our basic
policy in regard to the global environment.
We have also defined guidelines for activities related to environmental matters, based on this policy, which assist the practical implementation of these principles throughout our work.
■ Environmental Principles
" We aim to promote environmental protection and contribute to a better society,
while maintaining harmony with nature in our business activities. "
1
We will contribute to society by creating environmentally friendly technologies and products.
2
We will use the Earth's resources and energy sparingly, and never overlook environmental considerations when conducting our business.
3
We will play our part in improving the environment, hand in hand with local communities and society at large.
■ Guidelines for Action
●Creation of environmentally sound technologies and products
1
We are committed to the challenge of creating clean technologies, including those facilitating cleaner exhaust emissions, a reduction in CO 2 , the development of clean energy vehicles and alternative energy vehicles, and the protection
of the ozone layer.
2
We will encourage the creation of products that are environmentally sound throughout their lifespan, from the planning and development stages through to manufacturing, use, and recycling / disposal.
●Corporate activities for conserving resources and energy
1
In order to conserve limited resources, we will actively promote resource conservation and recycling activities.
2
We will strive to achieve diversified and efficient use of energy.
●Corporate activities in pursuit of a clean environment
1
We will not merely comply with environmental laws and regulations, but will also impose voluntary controls to higher
standards, and implement thorough self-regulated control.
2
In our pursuit of a clean environment, we will promote the development of new technologies and the introduction of
new systems which contribute to a cleaner environment.
●Working with others in the car-making industry to create a better environment
16
1
We will actively provide our employees with in-house education and information about environmental protection to
enhance their awareness of the global environment.
2
We will work in close cooperation with other car manufacturers in Japan and overseas to achieve better environmental
protection.
Promotion Plan for Environmental Activities, and Results of Activities for 2002
Mazda has established activities promotion plans in all areas and in relation to all aspects of our
work where we consider the reduction of environmental impact necessary, in both our corporate
activities and the use of our products.
Our activities promotion plans and our results for fiscal 2002 are shown below.
Subject
Environmental
management
Environmental activities promotion plan
Objective
Results during fiscal 2002
Related
pages
ISO14001
All manufacturing affiliates and suppliers to have
ISO 14001 accreditation by end of fiscal 2002
All 9 manufacturing affiliates achieved accreditation.
90%, or 337 of our major suppliers achieved
accreditation (109 more than previous year)
P18
・
P28
Fuel efficiency
Achieving Japanese 2010 fuel efficiency standards
in all weight categories of passenger car by fiscal
2005
Progress made towards achieving this. 17 types in
12 models have already achieved Japanese 2010
fuel efficiency standards.
P7
・
P24
Exhaust emissions
Raising the percentage of U-LEV passenger cars to
90% by the end of CY 2005
Introduced Demio, Atenza, Premacy and other ULEV cars. 12% of passenger cars sold were U-LEV.
P7
・
P24
Compliance with latest external noise regulations
All cars compliant
P25
Progress in clean energy car development
Hybrid (diesel engine and electric motor) truck displayed at 2002 Tokyo Motor Show
P10
Achieve a 90%-plus recyclability for all new models
from 2002 onwards
Atenza, Demio and RX-8 all have a 90%-plus recyclability
P30
Proactive use of recycled bumpers
Collected 40,358 damaged bumpers from dealerships within the market, which were used in component parts for new cars
P8
・
P30
Reduction in landfill
waste
Achieve zero emissions of landfill waste during fiscal 2002
All manufacturing bases achieved zero-landfill levels
P9
・
P26
Energy savings
Achieve a 5% reduction in CO2 output compared
with that of fiscal 1990 by the end of 2005, and a
10% reduction by end of fiscal 2010.
37.5% reduction achieved in comparison with 1990
standard.
P26
Reduction in CO2
emissions
Reduce CO2 emissions by improved efficiency in
logistics
A further reduction in CO2 emissions of 2067 tons
P29
Efficient use of
resources
Reduction in quantity of materials used through
simplification of packaging / wrapping materials
A further reduction of 992 tons of materials
P29
Compliance with Recycling Act
Research and development system in place to
ensure compliance with the Automobile Recycling
Act, due to come into force in 2005.
P30
Noise
Product development
/ R&D
Clean energy cars
Recycling
Manufacturing
Logistics
End-of-life vehicles
Recycling
17
Organizations and Systems
The Mazda Global Environmental Conference is responsible for the establishing of company-wide environmental polities
and company activities plans, and is the body with the highest decision-making authority in regard to such issues. Mazda is
engaged in rolling out various environmental management activities within each of its divisions, based on these policies and
plans. Member companies of the Ford Group also work together in alliances on certain issues.
In 1992, along with the establishment of the Environment-Related Activity
Promotion Plan, Mazda also established the Mazda Global Environmental
Conference. Based on policies and plans defined within this structure,
each division is engaged in developing its own environmental management activities.
The environmental management activities of each division are followed up
by the Hiroshima Area and Hofu Plant Environmental Committees. Issues
that require special attention on a company-wide basis are established as
designated projects. At present, we have convened a Recycling Steering
Committee, along with a Mazda Community Servicies Committee, both of
which are promoting activities of various kinds. Each company within the
Ford Group is involved in alliances with other companies based on particular issues such as development, manufacturing and logistics, according to
the issues faced by the company in question.
Progress in ISO 14001 accreditation
■ Organizational diagram
Divisional Environmental Committee
In order to improve our level of environmental compatibility and to reduce
the load placed by our work on the environment still further, not only our
Head Office but also our various project divisions are proceeding with
accreditation by the international regulations on environmental management known as ISO 14001. All our domestic and overseas manufacturing
bases had been accredited by fiscal 2000, and 9 of our major affiliates also
gained accreditation during 2002. Mazda is also promoting compliance
with and accreditation by ISO 14001 among our parts and materials suppliers, and as of fiscal 2002, 90% of them had been accredited in this way.
ISO 14001 Environmental Conference (Hiroshima / Hofu)
Research & Development divisions
Manufacturing divisions
Mazda Global
Environmental Conference
Purchasing divisions
(Chair: President of
Mazda Moter Corporation)
Logistics divisions
Sales divisions
Customer Service divisions
Administration
Recycling Steering Committee
Chair: Responsible Director
Secretariat
Mazda Community Servicies Committee
Chair: Responsible Director
■ Manufacturing bases in Japan
Hiroshima Area
Hofu Plant
Head office plant
Miyoshi plant
ISO14001
Accredited in June 2000
Nishinoura district
Accredited in September 1998
Nakanoseki district
Accredited in September 1999
■ Overseas manufacturing bases
ISO14001
Auto Alliance (Thailand) CO., Ltd.(AAT)
Accredited May 2000
Auto Alliance International, Inc (AAI)
Accredited June 2000
■ Main affiliates
[Automobile-related]
・Improvements in energy efficiency
・Reductions in exhaust gas emissions
・Reduction in external noise
・Development of clean energy vehicles
[Recycling-related]
・Reductions in quantity of environmentally harmful substances used
・Design for easy recyclability
・Recycling of materials
[Plant-related]
・Reduction in waste products
・Energy saving activities
・Clean manufacturing
・Rationalization of logistics
[Contribution to society]
・Support for volunteer activities
・Mazda Foundation etc.
ISO14001
Nihon Climate Systems Co., Ltd.
Accredited May 2000
Development and manufacture of air conditioning systems for automobiles
Mazda E & T Co., Ltd. (*)
Development, manufacture and retail of automobiles.
Design / testing of vehicle power trains.
Toyo Eitech (*)
Manufacture and sale of construction machinery and semiconductor-related equipment
Mazda Ace Co., Ltd. (*)
Security, insurance, refurbishing, maintenance operations
Malox Co., Ltd. (*)
Sea transportation, packaging, design and manufacture of automobile parts
Keyrex Rex Co., Ltd.
Accredited March 2001
Design and manufacture of automobile bodies and parts.
Microtechno Co., Ltd.
Accredited October 2001
Manufacture of engine pistons
Kurashiki Systhetic Chemical Industries Co., Ltd. Accredited December 2001
Development and manufacture of rubber parts for automobiles
Yoshiwa Industrial Co., Ltd.
Manufacture of automobile engines, chassis and drivetrain parts
Accredited April 2002
Companies marked (*) were accredited together with Mazda Hiroshima Area.
18
Environmental Monitoring
Mazda implements monitoring internal audits and external monitoring by an outside certification
organization, in order to confirm that the environmental protection activities implemented by each
of its plants under the management system for ISO 14001 are being operated correctly, and
according to its policies and plans.
Monitoring system
In order to be sure that environmental management systems are functioning correctly, we implement by internal audits and external monitoring by
an outside certification organization once per year. In the internal audits
process, certain management employees who have undergone training by
an external body and have attained designated qualifications in the field
are selected as internal auditors, and check our activities across the board
according to 180 comprehensive environmental categories. In our internal
audit activities for 2002, inspectors filed 22 incidences of minor non-compliance, and 64 observation categories, while in our external monitoring,
carried out by an organization registered to examine for ISO 14001 compliance, no incidences of non-compliance were recorded, although five
categories were noted as requiring observation. As well as reporting on
the results of these observation activities to top management, we are also
committed to implementing swift corrective measures.
■ Outline of check categories used in internal monitoring
Category
Planning
Facilities and
operation
Checkpoint
Impact on the
environment
●Has the indirect impact on the environment been correctly evaluated?
●Has indirect impact on the environment been correctly evaluated across all aspects of work?
Legal and other
requirements
●How are changes regarding designated facilities being handled?
●Are there any problems with the storage of designated industrial waste requiring special management?
Objectives and Targets
●Are environmental objectives and targets in line with environmental policy?
●Are long-term environment-related plans being reviewed and updated where necessary in response to changes in the company's situation?
Environmental
Management Program
●Is the program in line with other programs?
●Are appropriate measures being taken for unattained objectives?
●Is there evidence of the progress being made by the program?
Systems and structures
●Are divisional environmental management organizations in place? ●Are changes in management being handled appropriately?
●Is there a clearly defined alternative leader when the employee in charge of managing the project is absent?
Training / enlightenment
activities and skills
●What sort of training is planned for the current period? ●Is there a record of training?
●Is training offered to temporary and transferred employees?
Communication
●Are suggestions regarding the environment accepted from employees?
●What methods are used to ensure that all related parties within the organization are made aware of results of EMS monitoring and any reviews implemented.
Document management
●What methods are used to manage documentation? ●What methods are used to manage document distribution?
●What methods are used to store withdrawn (older versions of) documentation?
Preparations for and response
to emergency situations
●Is there a procedure in place for accident and emergency situations?
●Is training implemented to prepare for accidents? ●Is the procedure manual for accidents updated?
Non-compliance and corrective or preventative measures
●Are corrective measures implemented appropriately in regard to non-compliance issues raised in external monitoring activities?
●Are procedure manuals updated as a result of corrective and preventative measures implemented? ●Is there are record of corrective and preventative measures implemented?
Recording
●What methods are used to store environmental records?
●Are tertiary documents created within the division being periodically reviewed?
■ Results of internal environmental monitoring carried out in FY 2002
Minor incidences of non-compliance
Categories where observation recommended
(No. of incidences)
■ Changes in internal auditors
Hiroshima region
Hofu region
(No. of people)
400
20
64
350
15
63
300
10
48
250
5
200
72
335
287
ing
rd
co
Re
d
an
es
tiv
jec ts
Ob rge
d
ta
an y
res ilit
ctu ib
ru ns
St espo l
r
nta
me
on tee
vir it
En omm nd
C
a
on t
ati en
rv m
se ure
Ob eas
m
y
nc
ge s
er tion
Em itua
l
s
nta
me
on
vir ts
En spec
a
ns nt
tio me
era ge
Op ana
m
t
/ en
ng nm
ini te
Tra ligh
en
nt nt
me me
cu ge
Do na
ma
s
ram
Pr
0
150
272
og
As a result of internal monitoring, the following areas were highlighted and appropriate measures taken:●
Objective values are unclear and implementation timescales are inappropriate ●Environmental training
and education activities have not been organized ●Sufficient quantities of materials for emergency situations have not been secured
100
169
50
0
1999
2000
2001
2002 (Fiscal year)
19
Environmental Risk Management
Mazda believes that it has a serious responsibility to minimize environmental risk through its work,
by complying both with legal regulations and with its own self-imposed regulations, as well as having preventative and response measures in place for environmental incidents. For this reason, we
are pressing ahead with system organization and appropriate operation to achieve these goals.
Environmental risk management system
Environmental risks are present in both manufacturing aspects - manufacturing processes and facilities - and the product aspects of our work. Mazda is committed to minimizing the environmental risks in these areas, and
implements environmental risk assessments to ascertain necessary measures preventing pollution and environmental incidents. In addition to this,
we are training our employees in methods of dealing with emergency situations, in order to make a complete response to environmental risk.
Atmospheric pollution, water pollution, and pollution occurring as a result
of waste output are prevented through regular monitoring, as well as
countermeasures in place in our various plants and offices.
■ Environmental monitoring categories
Monitored aspect
Monitoring category
Frequency of monitoring
Air
Boilers, welding furnaces, heating
furnaces, drying furnaces, waste
product incineration furnaces, etc.
5 categories: SOx, NOx,
dust, hydrogen chloride,
dioxins
Approx. 400
times / year
Water
Waste processing water
44 categories including cadmium,
cyan, organic phosphates, lead,
hexavalent chromium and dioxins.
Approx. 1500
times / year
Sound /
vibration
Around plant perimeter
Levels of noise and vibration
Approx. 30
times / year
Odors
Around plant perimeter
22 categories including ammonia, methyl mercaptan, hydrogen sulfide, methyl sulfide.
Approx. 90
times / year
Waste
product
Slag, sludge, dust, etc.
28 categories including cadmium,
cyan, organic phosphates, lead,
hexavalent chromium and dioxins
Approximately
600 times / year
Responding to emergency situations
There were no environmental incidences during fiscal 2002.
Periodic inspections and emergency response procedures were put in
place at all plants and divisions where it was considered that there is a risk
of environmental pollution occurring, in order to allow appropriate measures to be taken in the event of emergency situations. We also implement
regular training to ensure prompt and appropriate responses within daily
activities to earthquakes and other natural disasters, and are constantly
updating and improving our response procedures in the light of this training.
■ Route for responding to environmental incidents and irregularities
Site check
and response
Site check and response
Incident
Strict adherence to legal regulations
There were no incidences of non-adherence during fiscal 2002.
Based on the standards for ISO 14001 management, Mazda promotes
improvements to its environmental practice on an ongoing basis. We also
impose autonomous regulations on our activities related to all environmental aspects that are stricter than either national or regional standards,
and work to adhere rigorously to these.
Disaster prevention center /
Response center
Person discovering
incident
Communication
Instructions
Request for
Support
Facility management
organization
Environmental specialist
organizations
Complaints regarding environmental issues
An initial verdict was reached in the Tokyo atmospheric pollution trial
relating to automobile exhaust on 29th October 2002, and the enquiry is
currently continuing on appeal.
Mazda received five complaints in regard to environmental matters in the
period under review. All of these related to odors emitting from our plants,
and were anonymous, but we have continued to implement thorough measures to reduce the odors being released during our operations through a
series of planned controls.
Products subject to recall for environmental reasons
There were no products subject to recall for environmental reasons during
fiscal 2002.
20
Emergency
contact network
Instruction
Communication
Instruction
Report
Person in charge of
environmental management
Report
Related Mazda and
external organizations
Director of environmental management
Education, enlightenment and communication activities
Mazda believes that that an improvement in environmental awareness is the starting point for all
environment-related strategies. For this reason, we are committed to environmental education and
enlightenment training activities.
Environmental education
Mazda implements a structured program of environmental education and
training activities for employees of all ranks, with the aim of assisting
them to be aware of their own positions within the organization, and prioritize work on environmental issues within their work. Environmental education begins from the time an employee enters the company, and continues to the manager, general manager and divisional manager level, with
curriculum based on our environmental management system.
We also support and take steps to proactively encourage our employees in
gaining external qualifications related to the environment. We implement
continuous education activities within our project divisions in order to promote a thorough awareness of the environment and develop our employees' capabilities in regard to operating our environmental management
system.
Management training
■ Environmental Education Structure
Department managers
Education at each level
Section managers
Group managers
Environmental
education
New employees
General employee education
Research education
Senior leaders course
Mazda Junior College course
Education for
qualifications
Education for employees in
designated occupations
Operations manuals course
Course for
Environmental Auditors
Accident response course
Course for
Internal Environmental Auditors
Course for
environmental-related qualifications
EMS promotion leaders' conference at the ISO 14001 office
Enlightenment / Communication
Enlightenment activities and reports, as well as information published in
our in-house magazine 'My Mazda', are communicated via our intranet
system to all employees, including those of affiliated companies, in order
to promote awareness.
In addition to this, we hold an 'Environment Month' every year in June,
during which the President of Mazda broadcasts a message throughout
the company, and we organize environmental exhibitions throughout the
company. In addition to these activities, employees join local clean-up
activities, and take part in environmental events with their families that
raise awareness. As well as including environmental data regarding each
of our automobiles on our official websites and product catalogs, we publish environmental reports and use various environment-related events to
communicate our awareness of and concern for the environment not only
to our customers but also to various external parties.
Automotive Engineering Exposition 2002
■ Participation in environment-related events during 2002
Event
Dates
Items displayed
1st - 2nd June
Premacy FC-EV
Automotive Engineering Exposition 2002
23rd - 25th July
Premacy FC-EV
'Living With Energy' Exhibition
31st August - 1st
September
Premacy FC-EV
Tokyo Motor Show
30th October - 3rd
November
Titan Dash
Clean Diesel Hybrid
Eco-Car World 2002
Premacy FC-EV at the Eco-Car World 2002 exhibition
21
Environmental Accounting
At Mazda, we publish environmental accounts in order to accurately understand the costs and benefits of our investment in environmental activities, and reflect these in further efficiency improvements. We also hope that this will help others to further understand the ways in which we are striving for environmental protection.
The cost of environmental protection
The cost of environmental protection is calculated from the costs involved
in reducing the burden on the environment, as well as investments to gain
benefits for the environment in the future, along with management costs
involved in issues such as project and product life cycles. The costs
involved in environmental protection during fiscal 2002 were as shown in
the following chart. In comparison with the previous year, our expenditure
on the prevention of global warming has increased.
The figures shown have been calculated using our own independent criteria, which in turn are based on materials relating to environmental
accounting issued by the Environment Ministry, such as their guidelines
and guidebook.
■ Environmental protection costs
Category
(Unit: 100 million yen)
Main activities
Costs within project areas
Pollution prevention
costs
Adherence to environmental laws / VOC emissions reductions
Costs of protecting the
global environment
Costs of reusing
resources
Investment
Costs
11.7
19.5
Prevention of global warming, prevention of damage to ozone layer, other environmental protection costs
8.5
12.8
Processing / disposal / reduction of waste products / recycling etc.
3.6
11.1
Water supply and wastewater
processing costs
Recycling of manufactured and retailed products / collection / recycling into products /
appropriate processing
0.3
1.8
Management activities costs
Environmental management system creation and operation / Monitoring and measuring
environmental loading / Environmental training and education of employees / Publishing
of environmental information and reports / Environmental education / training and maintenance of accreditation
0
6.7
Research & Development
costs
R & D of products that contribute to environmental protection / R & D of measures to
control environmental loading at the manufacturing and logistics levels / Attainment of
U-LEV level
14.4
298.3
Social activities costs
Environmental improvement strategies contributing to nature protection / increase in
greenery / preservation of scenery
Support for and reporting of information to local residents
Donations and support to organizations working to protect the environment
Donations to Mazda Foundation, and discussion meetings with local residents
0
1.9
Environmental damage costs
Costs of responding to environmental damage caused
0
0
38.5
352.1
Total environmental costs
390.6
＊Environmental accounting calculation criteria: 1) Scope of data collection: Mazda Motor Corporation stand-alone accounts 2) Facilities investment: Cash-flow management base, without depreciation / In categories straddling
more than one fiscal period, only the current period is included / In regard to facilities investment for multiple purposes, only the proportion related to environmental activities is included 3) Costs: personnel and general costs 4)
Research and Development costs: includes investment in facilities for R & D, general costs, personnel costs
22
environment by our manufacturing, logistics and management activities.
In fiscal 2002, in addition to our conventional calculation of benefits, we
also began the calculation of economic benefits arising from energy savings and reductions in materials use.
Benefits of environmental protection
This is calculated as the direct or indirect benefits reaped from the investments and costs incurred relating to environmental protection. In fiscal
2002, the following reductions were achieved in the burden placed on the
■ Environmental protection benefits
Environmental protection benefits
Category
Unit
VOC (volatile organic compounds) emission reduction
Fiscal 2001
Economic benefits
Fiscal 2002
Improvement level
Benefit details
Amount (100 million yen)
Improved by
4.5 g/m3
g / m3
8.0
4.5
Thousand tons CO2 /year
337.0
360.0
increase
6.8%
Tons CO2 / 100 million yen
24.7
23.4
Improved by
5.2%
Direct landfilled
waste
Thousand tons / year
11.2
4.9
Improved by
53.6%
Reduction in waste
processing costs
0.1
Incinerated
waste
11.0
10.0
Improved by
9.1%
Steam recovery
0.3
Waste removed
from site
89.9
85.7
Improved by
4.7%
Reduction in packaging
material
0.4
Recycled waste
%
96.5
98.3
Improved by
1.9%
Income from recycling /
sale of materials with value
Thousand units / year
38.5
40.3
Improved by
5%
Reduction in purchase of
materials
Emissions of CO2
(annual)
Energy saving measures
Emissions of CO2 per
unit sale
Reduction in waste products
No. of recovered
bumpers
13.2
32.9
0.2
Criteria for calculation of economic benefits: 1) Energy savings 2) Reductions in processing costs for manufacturing waste 3) In-house recycling and income from sale of materials with value 4) Reduction in purchase of materials, in regard to manufacturing and logistics processes.
■ Trends in environmental costs
Costs
Facilities investment
■ Environmental research / development costs
Movement in ratio
(%)
(100 million yen)
60
500
53.7
50
46.6
400
38.5
40
25.4
300
42.9
38.2
30
200
28.6
100
191.1
301.5
0
1999
386.7
20
352.1
2000
2001
2002 (Fiscal year)
■ Emissions of CO2 per unit sales
Tons CO2 per 100 million yen
27
0
(Fiscal year)
1999
2000
2001
■ Quantity of waste product emitted during
automobile manufacturing process
Tons / 100 million yen
9
25.9
8
8.5
25.3
7
24.7
24
6.5
6
23.4
23
6.6
5.6
5
(Fiscal year)
(Fiscal year)
22
2002
10
26
25
25.7
10
1999
2000
2001
2002
1999
2000
2001
2002
23
Research & Development
Mazda is working hard to achieve higher fuel efficiency and cleaner exhaust emissions, so as to
improve the environmental response of its products at the life cycle stage - usually the level at
which most impact can occur. In addition to this, we are working on reducing the use of substances
of concerns, as well as developing clean energy vehicles.
MISSION
1. Improvements in fuel efficiency
5. Reduction in use of substances of concern
2. Reductions in exhaust emissions
6. Work on LCA issues
3. Reductions in noise emissions
7. Improvement of the traffic environment
4. Development of clean energy vehicles 8. Promotion of recycling
Improvements in fuel efficiency
Reductions in exhaust emissions
Mazda believes that improvements in fuel efficiency and the reduction of CO2 emissions levels
are important issues in the protection of the
environment, and has set itself the target of
achieving Japanese 2010 fuel efficiency standards in all weight categolies of passenger cars
by fiscal 2005. In order to achieve this, we are
working on improved combustion in our
engines, higher efficiency in transmissions, body
weight reductions, and other issues, to provide
all-round solutions. Our newly developed, highly
efficient, all-aluminum 4-cylinder MZR engine (in
1.3-liter, 1.5-liter and 2.0-liter versions) has
allowed models of the Atenza released in 2002,
as well as our new model Demio, to already
achieve Japanese 2010 fuel efficiency standards.
In addition to this, our Premacy and MPV models also achieved Japanese 2010 fuel efficiency
standards during fiscal 2002, bringing to 12 (17
types) the total number of Mazda passenger
cars operating to this standard.
In order to contribute to improvements in air
pollution levels through reductions of pollutants
included in exhaust gas such as carbon monoxide (CO), hydrocarbons (HC) and nitrogen oxide
(NOx), Mazda is active in the research and
development of engine combustion, control and
catalyst technologies. We are pressing ahead
with the introduction of cars that meet the strict
standards applicable to low-emissions vehicles
(as defined by the Ministry of Land, Infrastructure and Transport).
Among our new cars released in 2002, all Demio
models achieved U-LEV ranking accreditation.
Our Atenza models were also all accredited as
U-LEV by July 2003. In addition to this, the RX8, which went on sale in April 2003, achieved ELEV standards throughout all models, as a
result of the introduction of the newly developed
rotary engine RENESIS, which achieves excellent fuel efficiency through the adoption of a
new sideintake and exhaust ports system.
●Trends in No. of Cars (models) accredited as
Designated Low Pollution Vehicles.
Mazda applied for registration under the low
pollution vehicle approval system implemented
by 7 metropolitan prefectures and cities, and as
of March 2003, 54 of its types had been accredited. We are also in the process of applying for
registration under similar Kyoto / Osaka / Hyogo
6 prefectures and cities Designation system.
■ Trends in the No. of Low-emission vehicles
introduced to the market (passenger cars)
(%)
100
E-LEV
12.0
G-LEV
80
60
52.8
40
40.5
20
18.1
0
25.2
1.9
9.3
2000
2002 (Fiscal year)
2001
■ No. of types designated as 7 Metropolitan Prefectures
and Cities Designated Low Pollution Vehicles
80
70
60
50
40
30
20
10
0
■ Transition in average fuel consumption by
weight class (for gasoline-powered cars)
U-LEV
1998
1999
2000
2001
■ Vehicles accredited as low-emission vehicles during fiscal 2002
(including RX-8, Atenza and Premacy models released in April 2003)
（km/R）
20
Passenger cars
Ultra-low
emission vehicle
(U-LEV)
15
Carol, Laputa, AZ-Wagon, Spiano,
Demio (2 types), Premacy,
Atenza Sedan, Atenza Sports,
Atenza Sports Wagon
Passenger cars
Excellent-low
emission vehicle
(E-LEV)
10
Carol, AZ-Wagon, Scrum Van, Spiano,
Familia Sedan, Familia S-Wagon,
Tribute, Atenza Sedan, Atenza Sports,
Atenza Sports Wagon, RX-8
Passenger cars
Commercial vehicles
Familia Van (3 types)
Familia Van CNG
Commercial vehicles
Scrum Van, Scrum Truck
Commercial vehicles
6
Fiscal 2000
1000
1250
1750
2000 Weight category(kg)
Fiscal 2001
Good-low
emission vehicle
(G-LEV)
1500
Japanese 2010
Fiscal 2002 Fuel Efficiency
Standards
24
2002
2003 (Year)
*Values calculated at the end of each year
Carol, Laputa, Spiano, AZ-Wagon,
Scrum Wagon, Premacy (2 types),
MPV (2 types), Familia Sedan,
Familia S-Wagon, Tribute, Millenia
Bongo Truck (2 types),
Bongo Brawny Van,
Titan Dash (2 types)
Reductions in noise emissions
Engine, exhaust system, intake system and running noise from passenger cars had all been
reduced sufficiently by 2001 to achieve compliance with the newest Japanese noise emission
regulations (those for 1998 - 2002), and during
fiscal 2002 we promoted the application of these
regulations to our commercial vehicles. As part
of these measures, we improved the rigidity of
our engine cylinder blocks, and also began fitting soundproofing covers and noise absorbing
under-covers to our engines.
Exhaust system noise reductions
Noise absorbing under-cover
・Three-layered construction of
silencer outer wall
・Addition of secondary silencer
Transmission side cover
Development of clean energy vehicles
Mazda is committed to the development of alternative fuel and clean energy vehicles. Since April
1998 we have been involved in joint development activities with Ford, Daimler Chrysler and
Ballard Power Systems, researching fuel cell
technologies, and in 2001, we initiated road
testing of our fuel cell electric vehicles known as
the Premacy FC-EV.
We have placed around 100 units of electric
vehicle on the market since starting our
16%
reduction
38％
22％
reduction
reduction
500
400
300
200
100
0
nza
Low-noise tires
600
Ate
Reduction of engine noise emissions
・Improved rigidity of cylinder block
・Improved rigidity of intake manifold
・Non-vibrating construction of
exhaust manifold cover
700
ella
・Increased capacity of air cleaner
・Addition and increase in capacity of
air intake noise damping equipment
Quantity of air conditioner refrigerant (g)
Cap
Engine area soundproofing cover
Intake system noise reduction
■ Reductions in use of air conditioner refrigerant
o)
2 emi
g. 0 l D
Au de
To w mo
(ne
io)
. 02 Dem
Jan el
To od
dm
(ol
2 ilia)
t. 0 am
Sep y, F
To emac
(Pr 2 ilia)
. 0 am
Jan y, F
To emac
(Pr
■ Noise reduction measures in the Bongo Van
research into such in 1966, and developed and
released the Bongo EV during 2002 as an addition to this lineup.
Mazda is also focusing on hydrogen as a source
of motive energy, and developed the hydrogenpowered rotary engine in 1991. We are currently
in the process of testing this vehicle and performing further research. In addition to this, we
are involved in the development of hybrid vehicles, and displayed our 'Titan Dash Clean Diesel
Hybrid Truck', which involves a combination of
the newly developed common-rail diesel engine
with an electric motor, and offers low exhaust
emissions and high fuel efficiency, at the Tokyo
Motor Show in October 2002. In addition to this,
we are pressing ahead with the sale of natural
gas-powered and LPG vehicles.
Work on LCA (Life Cycle Assessment) issues
Reduction in use of substances of concern
● Reduction in use of lead
Mazda is reducing the quantities of lead it uses,
so that when end-of life vehicle is processed for
disposal, lead contained in resulting automotive
shredder residue does not cause pollution. Mazda has eliminated the use of lead in the battery
cable terminals, heater core, radiators, as well
as the electrocoating paints and fuel tanks of all
new models it put on sale during 2002 (Demio
and Atenza), and has reduced its use of lead to
under one third the quantities recorded in 1996.
In addition to this, the same reductions have
been achieved in the RX-8, which went on sale
in April 2003, and is pressing forward with further reductions in its use of lead in new models.
● Reductions in use of air conditioner refrigerant
As part of its drive to reduce global warming,
Mazda has begun to fit its cars with air conditioner that require a reduced quantity of the
greenhouse-effect refrigerant HFC134a. During
fiscal 2002, we achieved a reduction of between
16 and 38% in the quantities of air conditioner
refrigerant being used in four models (Familia,
Premacy, Demio and Atenza).
LCA is a quantitative evaluation method of
impacts of a product on the environment at each
stage of its useful life, from raw material extraction, through manifacturing and product use by
the customer, to final disposal. Mazda is
involved in LCA-related research, as well as considering how to utilize LCA methods in order to
further reduce impacts of a product on the
emvironment.
Improvements of the traffic environment
Improvements to the traffic environment feature
high in our priorities, alongside the environmental safety of our products and manufacturing
methods. Improvements in traffic congestion
conditions, for example, allow reductions in CO2
emissions resulting from the wasted combustion of fuels. Mazda is participating in the ITS
(Intelligent Transport System) project, and in
addition to carrying out research into the future
of next-generation transport systems, is also
involved in the sales of VICS-compatible car
navigation systems and ETC equipment as
options on its cars, in order to promote the
widespread adoption of ITS.
Promotion of recycling
We are actively involved in research relating to
recycling technologies for damaged bumpers,
as well as improving the recyclability of our own
cars. Mazda is achieving excellent results in
these areas. Please see related pages for details
(P8 / P30 / P31).
25
Manufacturing
Mazda is striving for the efficient use of resources and energy, the minimization of emissions and
correct and appropriate processing and disposal of waste, in order to minimize the impact of its
work on the environment. During 2002, we achieved our aim of reducing to zero our direct landfilled waste, a year ahead of schedule. Other activities were as outlined below.
MISSION
1. The effective utilization of resources, and reductions in landfilled waste
2. Contributions to prevention of further global warming through promotion of energy savings
3. Promotion of environment-improving measures
4. Promotion of increased awareness of environmental issues among employees related to
project activities, and independent management of environmental issues by divisions
5. Living in harmony with the earth through environmental protection activities
Activities reducing the use of resources
●Objective and results / Fulfillment of zero
emissions declaration
Mazda had declared that it would reduce directly
landfilled waste from all its domestic manufacturing bases (including development, administrative and technical divisions) to zero level
(defined as less than 5% of that output in 1990)
by the end of 2003, but in fact, this was
achieved a year early, during fiscal 2002.
●Reductions in and recycling of by-products
and waste
In order to achieve our zero emissions target,
we focused heavily on reductions in quantities
of waste, and the recycling of waste product.
The main by-products of our manufacturing
processes include waste metal, mineral dust,
sand, and waste oil, among other products.
Waste metal has been reduced by minimizing
the size of sheet steel that is used to have parts
cut from it so that as little waste is produced as
possible, and then using the cutoff parts of
sheet steel in an in-house recycling process
whereby they are dissolved in cupola and recycled into parts. We also reuse plastics and
wooden pallets.
In addition to this, flammable waste produced in
our processes is incinerated in a thermal recovery furnace, and the heat recovered in this way
(as steam) is used effectively throughout our
plants. Mineral dust, coal ash and cupola slag
are used in cement and as soil improvement
materials outside our plants. Metals and casting
sand, plastics, waste paper and cardboard boxes are also recycled outside the plants. As a
result of these activities, we have reduced our
levels of waste output to 418,000 tons / year as
of fiscal 2002, with a total recycling ratio of
98.3%.
●Reductions in emissions and general waste
product
We have controlled our emissions of oil, cutting
fluid and sludge through separation, refining,
concentration and water extraction measures.
Emissions of waste paper, cans, plastic vessels
and other general waste output from our plants
has been significantly reduced through the
implementation of sorting and recycling.
■ Recycling of by-products and waste products resulting from our manufacturing processes during fiscal 2002.
Energy saving activities
●Objective and results
We have continued to work not only towards the
maximum possible efficiency in our use of energy, but also to achieve a 5% reduction in the
level of CO2 emissions compared to those of
1990 by 2005, and a 10% reduction by 2010.
Through improving the efficiency of our steam
supply and other measures in fiscal 2002, along
with a thorough and wide-ranging program of
efficiency drives in manufacturing plants, such
as the switching off of lights when not needed,
and appropriate temperature settings on air conditioning equipment, as well as variations in
production quantities and reviews of operating
systems, allowed a reduction in CO2 emissions
from our plants of 200,000 tons-CO2, or 35% in
comparison with 1990 levels. In comparison
with fiscal 2001, despite the fact that our sales
rose by a total of 12.7%, our increase in CO2
emissions was controlled to 6.8%.
●Changeover to LNG (Liquefied Natural Gas)
as fuel
At the Head Office Plant in Hiroshima, we completed the changeover to LNG for the plant power supply in December 2000, and we subsequently began the changeover process at the
Hofu Plant in May 2002. We are committed to
further reductions in the quantity of CO2 emissions created through the increased use of LNG
in the future.
■Cogeneration system (Hofu Plant Nishinoura
District In-house Generation System)
Electricity company
Raw materials / energy
(High pressure steam 88 t/h)
Substation
Plants
Products
By-products / waste products
In-plant recycling
(Electricity)
Generator
(20,000 kW)
Coal→
Boiler
Turbine
External recycling
(Low pressure steam) (Water supply)
100％
・Scrap metals
・Casting sand
68.0％
ash
30.3％・Coal
・Dust
Condensation /
waste heat
utilizing facility
1.7％
・Landfill
Waste products
Total recycling efficiency :
26
98.3％
Thermal
storage facility
(Condensation)
(Warm water)
Plants
(Low pressure steam)
Low pressure
boiler
Heavy
oil
■ Levels of CO2 emission from vehicle manufacturing process
600
560
565
■ Trends in CO2 emissions per turnover unit
■ Utilization of energy, by category
CO2 emissions per unit sale
(t / 100 million yen)
CO2 emissions levels
(thousand tons / year)
Diesel 21
30
LPG 88
550
A heavy oil 6
Coke 341
500
479
400
28
459
381
368
391
27.1
27.0
City gas 728
26.4
372
371
342
360
25.9
26
337
25.9
25.6
300
24.7
25.8
24
25.2
25.1
Total quantity of
energy used during
fiscal 2002
25.3
24.5
200
7,417
23.4
22
Electricity 4,970
C heavy oil 1,252
100
0
Gasoline 10
0
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002
(fiscal year)
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002
(fiscal year)
●Cogeneration system
This system uses fuel to produce and supply
steam, electricity and various other types of
energy. The system gives thermal efficiency of
60% to 80%, compared with around 40% when
generating electrical energy only. Mazda
installed the industry's first large-scale in-house
generation system at its head office plant in
1987, and in 1993, Mazda installed a new type
of Mazda-patented generation system in Hofu
Plant, which uses waste condensation heat, a
previously untapped source of energy, and is
capable of keeping up with the large fluctuations
that occur in demand levels within automotive
manufacturing plants.
Clean production activities
Mazda's production bases within Japan are all
located in the region of the Seto Inland Sea
National Park, which is blessed with a warm climate and beautiful scenery. Mazda understands
that the wonderful environment in which it is
located is part of the earth's heritage, and aims
for 'Clean Production' that will have minimal
impact on this environment. It is for this reason
that Mazda has instigated the following environmental protection systems, and continues to
make and improve plans for their operation.
●Advance inspection system for chemical substances
Before purchasing a new type of oil, chemicals,
paint or other such raw material or secondary
material, an advance evaluation of labor safety
and environmental aspects is carried out, based
on the material safety data sheet (MSDS). Mazda is committed to the elimination or reduction
in use of dangerous chemicals, and to finding
alternatives where possible.
●PRTR (Pollution Release and Transfer Register)
Mazda used 17 substances during fiscal 2002
that required reporting under the terms of
PRTR. In comparison with the previous year,
our production increased by 5%, but we maintained the trend towards reducing emissions,
and our releases of atmospheric or water pollutants grew by only 1% during the period under
review. (For details please see Site Data on
pages 38 - 41).
toilet,
handwashing
Human waste
septic tank
sterilization /
purification of human waste
Wastewater
processing facility
Oil separation
［Process］
cooling water,
waste washing water
Sub wastewater
storage tank
Wastewater transfer by pump
Main wastewater
storage tank
Coagulation
Wastewater transfer by pump
Organism processing
Initial rainfall
［Rainwater］
High level processing
Rainwater tank
●Prevention of sludge pollution in wastewater
Mazda has defined its own standards, which are
stricter than the legal regulations in regard to
wastewater pollution, and is in fact clearing
these standards by a certain margin, due to
strict day-to-day controls. Mazda also processes
its wastewater according to origin, as shown in
the diagram below, in order to preserve water
quality, categorizing wastewater according to its
origin in processing systems, domestic systems, etc.
●Prevention of atmospheric pollution
Mazda has defined its own standards, stricter
than legal regulations, in regard to SOx (sulfur
oxides), NOx (nitrogen oxides), dust, particulate,
mist separation, hydrocarbons and VOCs
(volatile organic compounds), and has introduced both removal equipment and low-impact
facilities, along with day to day management
methods that allow it to consistently meet the
demands imposed by these standards. (For full
details of emissions, please see Site Data on
pages 38 - 41).
●Prevention of aesthetic pollution
Noise, odors, and other aspects that affect the
aesthetic senses can upset people's sense of
wellbeing even if falling within the boundaries of
legal requirements. Mazda desires to live in
cooperation with the local community, and as
such is planning and implementing further
countermeasures and improvements to its existing activities.
●Other environmental countermeasures
Mazda is in the process of eliminating all chlorine-based substances from the cutting oils
used in its machinery processing plants. In
addition to this, we are committed to adherence
to the Waste Disposal and Cleanliness Act, and
currently store PCB (polychlorinated biphenyl)
for use as insulation oil for our condensers. As
of the end of fiscal 2002, Mazda had stores of
270 units of PCB.
■Outline of waste water processing (Head office plant)
［Domestic］
Quantity of energy used (x 103 GJ / year)
Released
Initial rainfall pump
Released
［Waste liquid］
Main wastewater
storage tank
coolants,
waste washing liquids
Vacuum truck
Incinerated
on-site
＊PRTR（Pollution Release and Transfer Register）
27
Green Purchasing
In order to truly lower our impact on the environment, a unified response is
required from both Mazda and its suppliers. Mazda is engaged in the following
activities to promote green purchasing.
MISSION
1. Promotion of ISO 14001 accreditation among suppliers
2. Purchase of environmentally friendly parts, materials and facilities
3. Survey of substances that impact the environment using IMDS standards
4. Reduction in paper use through increased introduction of IT
Promotion of ISO 14001
accreditation among suppliers
As part of its Environmental Management System, Mazda requires its suppliers of automobile
parts and materials, as well as suppliers of manufacturing facilities and equipment, to gain ISO
14001 accreditation. In order to promote this,
we share information regarding companies who
have introduced front-line environmental protection measures to their work, as well as encouraging our suppliers to become more aware of
the importance of the environment through various other methods.
As a result of these activities, a further 109 of
our suppliers gained ISO accreditation during
fiscal 2002, bringing the number of accredited
suppliers to a total of 337. We are encouraging
suppliers who are as yet unaccredited to move
as swiftly as possible towards the accreditation
process.
impact of each of its parts, materials and facilities, in order to reduce the burden placed on the
environment by its products, which are comprised of so many components. We are committed to studying and reducing the amount of
harmful substances included in our parts and
materials. We have also begun to purchase facilities and equipment that have been evaluated for
their energy consumption, as a further aspect of
our green purchasing activities.
use IMDS (the International Materials Data System) to study harmful substances related to our
work and to assist us in managing and reducing
the quantities of such substances used. The
system is now complete, and during fiscal 2003,
we intend to enter data regarding all materials
used in our automobiles to establish a complete
database.
IMDS
As one aspect of our efforts to use resources
wisely, we are working towards reducing the
amount of paper documents passed to our suppliers. Utilizing Mazda's information communications system 'MGN' (Mazda Global Supplier
Network), we began in December 2001 to
replace paper document (order book) distribution with electronic versions of documents, as
the first step in this process. The second step
involves digitalizing the purchasing administration process that takes place between Mazda
and its suppliers (involving electronic verification, electronic document storage, etc.). This is
allowing us to improve the efficiency of our twoway communications with suppliers. As a result,
at the end of fiscal 2002, we found that we were
saving 310,000 sheets of paper per month in
comparison with levels in fiscal 2000.
Mazda considers it extremely important to
understand and evaluate the environmental
Mazda is constantly engaged in improving its
environmental management system through
working together with its suppliers to improve
green purchasing. We have already collected
data from our suppliers regarding all environment-impacting substances contained in automobile component parts, and are working on
fully understanding the implications of these. In
addition to this, during fiscal 2001, we completed surveys clarifying the quantity of substances
to be regulated in Europe from July 2003 (lead,
mercury, cadmium, hexavalent chromium) in
each of our automobile parts. We have begun to
■ Status of suppliers accredited for ISO 14001
■ Studying our use of
environment-impacting substances
Purchase of environmentally friendly
parts, materials and facilities
400
337
companies
350
300
Requests survey
Increased by
109 companies
228
companies
250
200
Purchasing
supplier
Mazda
Data
download
162
companies
Data
input
150
104
companies
100
50
0
28
IMDS server
2000
March
2001
March
2002
March
2003
March
Reduction of paper use through
increased introduction of IT
Logistics
Logistics covers the whole range of our activities, from parts purchasing to the
sale of products, and we are working hard on various strategies to improve the
effectiveness of our environmental response in this area. We are committed to
further progress towards the realization of clean logistics.
■ Use of electric
vehicles in logistics
Total No. of vehicles No. of electric vehicles
MISSION
239
673
369
137
1,418
Trucks
Forklifts
1. Reduce our use of energy and CO2 emissions through greater efficiency in logistics
Towing tractors
2. Promotion of simplification and returnability in packaging and wrapping materials;
Other
recycling of such materials in order to reduce quantities used
Total＊
0
130
369
137
636
＊Subcontractors handle transport of parts and completed automobiles, and Mazda does not own such transport vehicles.
＊Vehicles used for on-site transport/parts procurement.
Reduction of CO2 emissions through
rationalized distribution processes
We are considering all our logistics areas in the
light of their environmental impact.
■Manufacturing / purchasing logistics
We have been working on the rationalization of
our logistics through a modal shift to using JR
freight trains and shipping lines to bring component parts to our plants from suppliers located a
significant distance away. During fiscal 2003,
we will be introducing a 'milk run' type cyclical
collection and delivery system based on our distribution centers, to bring about further efficiency improvements. We have facilitated a reduction in the number of distribution trucks being
used through the introduction of highly loadefficient semi-trailers. This gave us a reduction
in CO2 emissions during fiscal 2002 of 2,542
tons / year.
■Completed vehicle distribution
Mazda has conventionally utilized the location of
its plants, which are coastal, to ship large quantities of automobiles to areas other than those
immediately local to us by sea. More than 80%
of our total transportation of automobiles is
done using these sea routes. At the same time,
we are also implementing joint distribution with
other companies, along with other efficiency
improving measures for distribution, including
return carriage transportation, based on 11 distribution bases in regions throughout Japan.
This allows higher efficiency and lower costs, as
well as promoting the rationalization of all our
activities relating to the delivery of new cars to
customers. The creation of this optimized logistics system is enabling us to further reduce the
burden placed on the environment.
(Expansion of joint distribution with other manufacturers)
We have been promoting the joint use of our
shipping routes by other manufacturers since
1999. These activities achieved a saving of 212
tons / year of CO2 emissions.
(Elimination of paint protective film materials
during transportation)
Conventionally, new cars being shipped for sale
were protected using car wax or protective film.
Mazda has developed a paint that does not need
such protection, in order to reduce our use of
packaging and chemical substances. This was
introduced in 2000, and in 2002 we eliminated
the use of paint protective film on further models and to further destinations.
■KD (Knock-Down) distribution
Mazda's KD manufacturing parts, which are
bound for overseas assembly plants, as well as
parts being sold to overseas manufacturers,
have conventionally been transported to Kobe
by truck and domestic shipping lines, before
being loaded onto export ships and sent to their
destination from Kobe port. Since 1998, we
have introduced a global shipping system that
allows us to ship direct to Busan (Korea) and
Kaohsiung (Taiwan), loading items for export
directly onto ships leaving Hiroshima. This gives
a reduction in fossil fuels used for domestic
transportation, and therefore a reduction in both
CO2 and NOx emissions.
■Distribution of parts to customers
Since 1994, a changeover to increased joint dis-
tribution and rail distribution systems has
allowed Mazda to achieve increased efficiency
as well as reductions in emissions. In addition
to this, we began to deliver to a single centralized location rather than the original 9 centers
located in the metropolitan Tokyo, Yamanashi,
Saitama and Gunma areas, allowing an increase
in truck loading efficiency as well as a reduction
in the numbers of trucks on the road. Since
June 2000, we have also been delivering supply
parts to this single location by rail, further
reducing CO2 emissions.
Reductions in packaging and wrapping materials
When Mazda automobile parts are shipped to
overseas knockdown plants or sales companies
within Japan, they are now packed using
reusable packaging materials. We are making
the changeover to reusable materials and a
reduction in use of wooden pallets, based on
our principles of 1) Returnable, 2) Reuse and 3)
Reduce, in order to make savings in the area of
resources use. (Please see page 11 for details of
results during fiscal 2002).
■ Logistics diagram
Mazda
Parts manufacturer etc.
Pure car
carrier
Distribution center
Dealership
Domestic
customer
Ship
Depot
Dealer
Overseas
customer
KD pool
Local port
Overseas plant
Service parts distribution
Parts dealership
Dealership
Domestic
customer
Distributor
Dealership
Overseas
customer
Finished automobiles
Manufacturer
Finished automobile pool
Railway
Between or within plants
Manufacturer
Low-polluting
semi-trailers
Shipping
Plant
KD distribution
Ship
Plant
Manufacturer
Base
Parts center
Manufacturer
Ship
29
Activities to Promote Vehicle Recycling
Mazda is considering its corporate responsibilities in the light of the Automobile Recycling Act, to be passed in January 2005, and is working on improving its damaged
bumper collection and recycling program as well as other aspects.
Acceleration in vehicle recycling
The Recycling Act, or laws relating to the recycling of end of life vehicles, was announced in
July 2002, and is scheduled to come into effect
in January 2005. Automobile manufacturers are
required to play a central role in the development of relevant recycling systems, and will be
required to remove fluorocarbons, airbags and
ASR＊ from vehicles they have manufactured
once they reach the end-of-life and recycle or
dispose of them appropriately. Mazda is playing
an active and cooperative role in the foundation
known as the Japan Automobile Manufacturers'
Association, which is an organization comprising related industries, with the aim of achieving
a smoothly operating general recycling system
for automobiles.
In addition, in order to raise the recyclability,
Mazda is pressing ahead with the development
of component parts that use increased quantities of recycled materials, as well as technologies for the recycling of plastics and rubber.
＊Automobile
Shredde Residue
Attainment of a 90% recyclability in
new models released since 2002
Appropriate collection and disposal
of fluorocarbons
According to the Automobile Recycling Act, endof-life vehicles will be required to be a minimum
of 95% actual recycling rate by 2015. Mazda
takes this principle seriously, and set itself the
task of achieving a 90% recyclability in all its
new models released from 2002 onwards. This
has been achieved in Atenza, Demio and RX-8
models.
In response to the fluorocarbons Collection and
Disposal Act of October 2002, Mazda is working
in partnership with other automobile manufacturers to cooperate on the creation of an automobile fluorocarbons recovery and disposal
system for fluorocarbons used in car air conditioning units.
We are also giving guidance to all our dealerships in regard to adherence to regulations surrounding the reporting of fluorocarbons recovery results to local governing authorities, subsequent to the fluorocarbons regulating laws that
were passed in June 2003.
Collection of damaged bumpers and
bumper recycling
Mazda has been collecting unwanted damaged
bumpers that accumulate within its dealerships
when cars come in for repair and recycling them
into parts for its automobiles since 1992. During
fiscal 2002, we collected 40,358 bumpers. In
addition to this, through removing the external
colored paint film from the surface of the
bumper, we have been able to create a bumper
strengthening component that has higher
mechanical strength than previous such parts,
and these have been used since February 2001.
Furthermore, we achieved an even higher quality
of recycled bumper in July 2002.
CFC collection equipment (for use with
HFC134a and CFC12)
■ Automobile Recycling Law
(Act pertaining to resource recovery and
other aspects of end-of-life vehicles)
Recycle charge
paid in advance
Charges
invoiced
paid
Instrument panel
Vehicle
owner
中古車
Vibration welded for ease
of removal
Second hand
vehicle
Final owner
Cancellation of
legal vehicle registration
Capital
management
foundation
Charges
End-of-life
vehicle
Receiving agent
Automobile manufacturer / importer
CFC
CFC gas collection agent
(collects CFC gases using
Collection charges paid
Airbag
Collection charges paid
■ Illustration of improvements to recyclability of plastic components fitted to Atenza models
B pillar trim
Trunk side insulator
PP and PUR easily separated through change
in adhesion method
Change of adhesive allowing
easy separation of PVC and felt
Dashboard insulator
Change of adhesive allowing
easy separation of PVC and felt
appropriate methods, and returns
them to the manufacturer)
Wrecking agent
(removes parts suitable for
recycling, airbags, etc., and
Reusable
parts etc. Usable parts market /
usable metals market
hands these to manufacturer)
Door trim
Improved ease of separation through single
material (PP) construction and modularization
Trunk board
Changed from PET surface to
single material PP construction
Floor mat
Shredder dust
Shredding agent
(shreds vehicle using method appropriate for recycling, hands over
shredder dust to manufacturer)
30
Metals etc.
Change of adhesive allowing easy separation of PE and felt
PP
Polypropylene
PVC Polyvinyl Chloride
PUR Polyurethane
Rear console
PE
PET
Polyethylene
PET resin
PP and PVC easily separated through
change in adhesion method
The challenges facing dealerships
Our dealerships are working hard to comply with environmental laws and contribute to the cleaning
of the environment, through self-imposed targets. They are also contributing to our work at saving
the environment, through the collection of damaged bumpers and CFC recovery.
●Definition of MECA 21 indexes for autonomous
activities
Mazda created MECA 21 (Mazda's Environment
Care Approach 21) in cooperation with the Mazda Dealership Association, in order to have a set
of indexes for autonomous environmental activities. Dealerships are required to gain certification according to these indexes to show that
they are working towards environmental goals.
In order to support dealerships working positively towards MECA 21 goals, Mazda has also
produced a behavioral manual for dealership
sales and service staff known as the Mazda
Excellent Navigator, as well as a collection of
examples of excellence in regard to environmental regulation adherence and environmental
improvement.
Mazda Excellent Navigator
●Bumper recovery and recycling
Damaged bumpers that are produced during
repair or replacement work are collected from
dealerships throughout the country and are
used as resin parts in new cars.
●Collection and disposal of designated and
alternative CFCs
All dealerships have been fitted with collection equipment for CFC12, which has been designated as a particularly damaging substance for the ozone layer, and
the alternative gas HFC134a, which is known to
cause greenhouse effects. Appropriate recovery and
disposal of these gases is currently being carried out.
■ Flow of bumper recovery and recycling
Recovery
request
Dealership
Shipping company
Purchase
Grinding plant
Recovery
Recycled parts
purchase
Mazda (Inc.)
Parts supplier
Recycling plant
Reuse / sale
Reuse of bumper pallets in component parts
Ground bumpers formed into pallets
Collection of ideas regarding compliance with environmental laws and
environmental improvements (New 6S)
Fluorocarbons recovery at a dealership
The Green Office
Since beginning the challenge of gaining ISO 14001 accreditation, each of our offices has been working hard to promote
activities that lessen the burden on the environment.
MISSION
1. Reduction in electricity use within offices
2. Reduction in amount of paper purchased for computers
3. Thoroughly implemented sorting of waste
Main activities in progress to reduce
the burden on the environment
work flow processes that can be done on individual computers.
●Reduction in paper use
● Various types of information being stored on
intranet sites, and progress made in changing
over to electronic data
● Administrative processes and accounting /
bookkeeping being changed over to shared
●Recycling expansion
● Use of shredder dust (waste paper) in packaging materials
● Increase in quantity of paper recycled through
sorting of waste paper
●Promotion of energy saving
● Thorough implementation of switching lights
out when not in use
● Expansion of anti-idling campaign for vehicles
on site
31
Safety Issues
Product Safety
Our policy is to offer the maximum possible safety in a way that is appropriate to the product, in both areas of active safety
(driving safety) and passive safety (safety of passengers). We are also concerned with safety from a holistic viewpoint, and
are pressing ahead with research and development of technologies that ensure the safety of pedestrians and the traffic
environment as a whole.
Our philosophy of vehicle safety
Safety Technology
Mazda holds the concept of safety as central to
its work in car manufacturing, and for this reason is concerned to offer the highest levels of
capability possible in all aspects. Mazda aims
for safety at the highest levels. For this reason,
we develop and implement safety regulations
that not only meet but exceed those of the countries in which we work. In order to further
improve our research and development into
safety issues, we established a Safety Development Promotion Committee in 1990, who are
responsible for defining our safety policy.
■Active Safety Technology
Mazda supports control performance through
technologies such as 4W-ABS and EBD (Electronic Brakeforce Distribution system) systems,
as well as utilizing DSC (dynamic stability control) to prevent cars from slipping sideways.
These systems promote extremely safe driving.
Furthermore, Water repellent glasses and selfleveling high intensity Gas discharged headlamps also raise driver visibility.
Safety policy
Based on the awareness that safety is a primary
requirement for the enjoyment of life with automobiles, we commit to the following:
1) Research into methods of automobile use by
customers and the social and traffic environment in which such automobiles are being
used
2) The search for ever-safer technology, and the
application of such in ways that are most
appropriate to our customers.
This safety policy is the basis for Mazda's
'Active Safety Technology', in which we work to
proactively prevent the occurrence of car accidents, as well as our 'Passive Safety Technology', which seeks to minimize damage to passengers in the case where an accident does occur.
In order to prevent traffic accidents, we believe
that a holistic approach to automobiles and the
traffic environment, as well as a focus on human
behavior, is necessary when considering safety
issues. The achievement of an efficient and safe
traffic environment will, we believe, also contribute to a lessening of the burden placed by
automobiles on the environment. Mazda is
working on safety technology for the future
using the most cutting edge techniques currently available. We are also participating in the ASV
(Advanced Safety Vehicle) and ITS (Intelligent
Transport Systems) development projects being
promoted by the Ministry of Land, Infrastructure
and Transport.
Safety verification
We implement various verification tests on our
cars to ensure that we are building in genuine
safety. Our testing includes the use of supercomputers in crash testing, a decelerating collision simulator, and various types of crash tests
using actual vehicles. We are working hard to
ensure that we are able to deliver products that
offer the utmost in safety to our customers.
■Passive Safety Technology
Our developers are working on an automobile
body with a 'crashable zone', which is able to
absorb impact on collision, along with a rigid
triple H construction, which can be combined to
give a highly rigid safety body. This is being
developed further to offer greater guarantees of
safety to passengers.
Within the car, we are pressing ahead with the
introduction of various features to preserve the
safety of passengers such as front seat belts
with pretensioners and load limiters, Energy
Absorbing Upper Interior, Neck injuly reduction
Bonnet used in crash testing aiming for pedestrian protection
■ RX-8 - safety measures that protect in collision
The energy absorption of the lightweight aluminum bonnet has been improved by the inclusion of many shock cones, in order to minimize damage to pedestrians if hit by the car.
The crushable brake pedals reduces
the chance of foot, ankle and lower leg
injulies by minimizing brake pedal intrusion
Front seat belts with pretensioners and
load limiters, and dual stage type driver's and front passenger's seat airbags,
with a two stage inflation control, are
fitted in all models as standard
Energy Absorbing Upper Interior used on
pillar and roofside trim to absorb impact
Top tether anchor ISO-FIX compatible child seat fixed within car
Neck injuly reductionseats
In a frontal collision, the impact energy is dispersed in three directions
throughout the front of the cabin in
order to reduce malformation of the
body
32
seats, dual-stage frontal airbags for driver and
front passenger seats, curtain-shield and front
side airbags, among other items. Mazda is also
concerned with pedestrian protection, and is
working on developing body design that reflects
these concerns.
If the car is subject to collision in the 'crashable zone',
the impact is absorbed, and the strongly assembled
floor / side / roof H-shape construction controls cabin
deformation. This highly rigid and safe body construction has been uniquely developed by Mazda.
The use aluminum strengthening materials inside the rear door and the highly tensile, vertical
built in pillar gives the RX-8 the same or better
side strength, despite it having no center pillar.
Safety Issues
Health and safety
A safe and healthy workplace, leading to a vital workforce, is the basis of all our activities. Mazda
holds respect for human beings as the basic principle behind its work, and began working towards
a target of zero accidents in the workplace more than twenty years ago. At present, we are broadening the horizons of our activities and aim to continually improve our safety standards.
Promotion of health and safety activities
throughout the company
Mazda works hard to ensure that the wellbeing
of our employees on both a workplace safety
level and an individual level is maintained,
through activities designed to encourage
employee participation.
These activities relate to the five categories of
safety, hygiene, health, accident prevention and
transportation. Each year we establish a plan for
these activities and our various divisions are
involved in implementing activities accordingly.
Results are reported periodically to the Health
and Safety Committee, who work on improvements according to a thoroughly implemented
PDCA (Plan Do Check Analysis) cycle.
■Safety
Aiming for a safe and accident-free workplace
through management of time lost and accident
statistics.
■Hygiene
Aiming for improvements in areas of the workplace that may be subject to health concerns,
and the creation of a comfortable workplace.
■Health
Careful planning of physical and mental health
management for individual employees, with the
aim of reducing sick leave.
■Accident prevention
Aiming for the prevention of accidents and fires
through risk management
■Transportation
Aiming for improvement in traffic safety awareness, along with an increased awareness of
safety issues when driving among all people.
Health and Safety Activities
Promotion System
This system offers management support to
employees in management or directorial roles
for health and safety issues. It was introduced in
1994 to encourage sustained improvements in
such activities. The system evaluates activities
in 16 categories such as health and safety related regulations, company rules, activities strategies, etc., and promotes management as well as
clarifying the roles of employees in various
ranks, in order to promote improvements to the
processes.
We are able to evaluate the level to which PDCA
is being implemented through quantifying management evaluations in this way.
The All - Mazda Health and Safety Conference
Activities during fiscal 2002
During fiscal 2002, we began the second stage
of the All-Mazda Zero Accidents campaign. We
have attained most of the targets set, as well as
achieving registration under the terms of the
Ministry of Health, Labor and Welfare's Type 4
Accident Free Record at our head office and
head office plant. We sustain a record of 23.7
million accident-free hours.
Workers and top management visit the workplace together to look at
health and safety issues
■ Trends in no. of accidents in the workplace
Year
No. of accidents
No. of working hours lost
1999
9
0.20
2000
8
0.19
2001
6
0.16
2002
3
0.11
■ Organizational diagram (company-wide staff)
Overall directorial manager
for health and safety issues
General Manager,
Personal & Human Development Div
Health insurance union
General manager
for health and safety issues
Safety manager
Hygiene manager
Health manager
Safety team
Hygiene team
Health management center
■ Trends in sick leave
Year
Ratio of leave taken
1999
12.1
2000
12.1
2001
10.1
2002
7.7
33
Community Activity
Contribution to the Community
In aiming to be an enterprise trusted and loved by the community in its role as a good corporate citizen, Mazda is engaged
in a wide array of activities that contribute to the community. We are promoting activities from volunteering to humanitarian
contributions, all of which fit the needs of our regional communities. We are also engaged in supporting science and technology and the promotion of well-rounded youth through the Mazda Foundation.
The basic role of a corporation is to provide
products and services that are useful to society,
and to bring about economic benefits that
improve people's lifestyles, culminating in a
contribution to the overall flourishing of society
as a whole.
As well as being an economic entity, however, a
company is also a social entity. Mazda's vision
is to continue to bring joy and passion to our
customers through creating new values and
providing the best in automobiles and services.
Through these corporate activities, it also strives
to be trusted and loved by the community as a
good corporate citizen, as it makes various contributions to social activities.
Mazda Specialist Bank
The Community Services Committee promotes
contributions by people as its main principle.
We established the Mazda Specialist Bank in
1994 to assist regional communities in planning
and implementing events and activities for
which specialist knowledge may be helpful, with
the aim of assisting the facilitation of such activities.
Employees of Mazda or our group companies
with particular knowledge, skills or abilities as
well as talents or interests that they have developed over the years, are registered at the Specialist Bank, and are dispatched in response to
requests for help from community members.
The Mazda Community Services
Committee
Mazda believes it is important to develop positive and long-lasting activities that are suited to
the needs of the regional community in which it
operates, as part of its contribution to society.
This allows Mazda to share its joy and excitement with others, and to proceed on a course
hand in hand with the community. Mazda
believes that community activities such as these
are an essential role that the company must play
as a good corporate citizen.
To provide a basis for this, Mazda formed the
Mazda Community Services Committee in 1993,
composed of representatives from related corporate sectors at Mazda and Group companies,
and with a company director as chair. Decisions
regarding Mazda's community services are
made based on the work of this and the Promotions Committee, which handles operations. The
main feature of our community service is "The
Contribution of Human Resources Matching
Regional Needs."
Registrations are done under four categories of
professional speciality (divisional), professional
speciality (individual), sports and culture / other,
and from these categories employees are dispatched to give lectures on the environment,
teach lessons in schools, instruct in issues
relating to health management, give sports
training, and perform at regional cultural events.
Our specialists are active in a wide range of
community contributions.
Since its foundation the Specialist Bank had
placed a total of over 1500 employees into community situations as of March 2003. During fiscal 2002, a total of 263 employees took part in
this scheme.
●The Mazda Community Contributions Tree●
The Mazda group is committed to various activities rooted in the communities in which it operates.
Academic
education
Culture and the arts
Lecture meetings (Mazda Foundation)
● Support for Hiroshima Symphony Orchestra etc.
Scientific and technological research support (Mazda Foundation)
● Well-rounded youth research support (Mazda Foundation)
● University lectures (Mazda Foundation)
● Dispatch of teachers to Junior and Senior High schools etc.
●
●
International
Exchange
Environmental protection /
disaster prevention
●
●
Community cleanups and cleanups around company facilities
Cooperation through dispatching of in-house fire engines /
ambulances to community situations etc.
●
● Mazda / YFU scholarship program
Investment / personnel placement in international exchange organizations
● Scholarship support for overseas students, etc.
Regional
development
Social welfare /
medical care
Investment and dispatch of personnel to regional economic foundations
● Support for youth and civilian activities (Mazda Foundation) etc.
●
●
Donation of automobiles / wheelchairs for disabled people
● Opening of Mazda Hospital to local community, etc.
Regional
exchange
Sports
Sponsorship of Hiroshima Carp Baseball Team
● Investment and personnel placement into Sanfrecce Hiroshima Soccer Team
● Community Ekiden (long distance relay race) hosting, etc.
Participation in Hiroshima Flower Festival
● Opening of Mazda Museum to the public, etc.
●
●
Mazda Group
Mazda
Volunteer Center
Mazda
Specialist Bank
The Community
Basic
Philosophy
for Activities
34
To bring vitality to the local economy and industry
through corporate activities. To work for cooperation and
symbiosis with the region, and to contribute to the creation of a prosperous community as a corporate citizen.
Activity
Policies
●
Activities attuned to local needs
●
Emphasis on volunteer activities by employees
●
Alliances with other companies in the Mazda Group
●
Expansion of opportunities for interaction
●
Emphasis on continuity
with the local community
Community Activity
■ Outline of the Mazda Group Community Services Activities
Mazda Foundation
Mazda Community Services Committee
Secretariat
(General Affairs Div.)
Mazda Specialist Bank Activity
Mazda Specialist Bank
Group Promotion Committee
Mazda Volunteer Center
Registration
Registration
Group and company regional contribution activities
Group employees / ex-employees
Regional development support
Regional exchange /
international exchange
Improvements to the environment /
social welfare
Culture / education / science / sports etc.
Regional society
The Mazda Volunteer Center
The Mazda Volunteer Center was formed in
1996 to support Mazda employees in their volunteer activities. Company or group employees
register at the center if they wish to become
involved in volunteer activities, and are dispatched to help regional groups when requests
are received for volunteer assistance. In contrast
to the Mazda Specialist Bank, whose members
use their particular skills to meet regional needs,
the Volunteer Center aims to place employees in
situations where they will work alongside the
people of the local community, in order to gain
experience and empathy with local residents.
Some examples of work done by volunteers
include regional cleanup and environmental
improvement activities, as well as assistance at
welfare events, hosting visitors from overseas
during international exchange events, and helping out at local festivals. Our volunteers are
involved in a wide variety of humanitarian contributions to the local community.
The Mazda Foundation
We established the Mazda Foundation in 1984 to
promote science and technology, help nurture
young people, and contribute to the creation of a
society where the peoples of the world can
prosper together and lead enriching lives.
With a focus on research aiming for the creation
of a recycling society and the revitalization of
civilian activities, the Foundation supports conferences and study meetings organized by
young researchers, as well as civilian activities
rooted in local communities. It also supports
research exchanges between Hiroshima University and various other universities in Asia, as
well as funding lectures and study meetings at
universities in the Hiroshima region. The Foundation also works in partnership with other corporations and groups in Hiroshima City to run a
scientific experience camp for young people,
aimed at stimulating creativity. The assistance
so far provided by the foundation totaled 954
grants and 923.4 million yen, as of the end of
fiscal 2002.
●Total research grants awarded during fiscal 2002
Applications for research funding were made
from universities throughout Japan in 2002, of
which a total of 30 applications relating to the
promotion of science and technology, as well as
one specific project, were given grants totaling
36 million yen. In addition to this, four applications relating to research into young people's
health and development were given grants totaling 3 million yen. In total, 35 applications were
given grants totaling 39 million yen.
●Details of research supported during fiscal 2002
《Support for the promotion of science
and technology》
Support was given to 30 projects considered
excellent in the field of promoting science and
technology. Of these, eight projects in the field
of recycling and resource management engineering were selected for particular focus by the
Mazda Foundation, including the first-ever production of cellulose self-reinforcing composite
material and the discovery of its functionality the production of environment-friendly composite material made only from vegetative matter
aimed at replacing plastic material (a project of
Kobe University) and research into red tide prediction systems using modeling of marine
resource cycles and marine microorganism
ecosystems, that aims for the accurate prediction of red tides (a project of Hiroshima City
University). The Asian overseas research pro-
Mazda Specialist Bank :
An employee giving a lecture at a local junior high school on environmental issues
■ Fiscal 2002
Specialist Bank support
Year
1998
1999
2000
2001
2002
No. of personnel
dispatches
315
329
238
196
263
Society and business
26%
Performing arts
25%
Environment and technology
10%
Health and medicine
9%
Sports
6%
Lectures on international
relations and overseas markets
4%
Other lectures and Instructions
10%
gram titled "Engineers Across Borders," being
implemented by Hiroshima University for technology related students, was also awarded a
special grant according to the Foundation's
focus on support for Asian Regional Tertiary
Education.
《Support for the healthy development of
young people》
Similarly to 2001, the activities selected for
grants focused on practical research helpful to
the vitalization of citizen activities for the promotion of well-rounded youth. These four projects
included activities such as "Project study and
creation of a learning community for children at
school on Saturdays" (Kansai University), and
"research into the elimination of negativity
toward volunteer activity" (Hijiyama University).
●Support for local citizens' activities
during fiscal 2002
The Foundation supported 18 projects deemed
to offer encouragement to the holistic development of young people taking on responsibilities
of the next generation, and rooted in the local
community. A total of 5.8 million yen was paid
in grants to these projects. Of these, six were
related to the Foundation's particular interest in
the environment, including a 'Hand-Made Museum - Regional participatory educational activities that teach us about the environment', and a
project entitled 'Rainbow Nature School - A
Sense of Wonder'.
Mazda Volunteer Center :
Participation in a regional cleanup campaign by workers and management
35
Mazda's History of Environmental Activities
Activities relating to cleaner emissions
●1962 (Feb) Cross-flow engine used in Carol 360 to reduce CO emissions.
Activities relating to the development of clean energy cars
●1966 R&D into electric vehicles begins.
●1968 Prototype of electric Familia van
completed.
●1970 (Jan) Ten Familia van EVs delivered
to Nippon Telegraph and Telephone Corp.
(as service vehicles for communications
facilities at the Osaka World Expo).
●1965 Emissions Response Research
Committee established.
●1970 (Oct) EX005 hybrid automobile
exhibited at Tokyo Motor Show.
●1966 (Aug) Blow by gas reduction device
mounted in Luce 1500.
●1967 (Dec) Exhaust Gas Research Center
opened.
●1971 (Apr) Mazda joins R&D project into
electric vehicles organized by the MITI
Agency of Industrial Science and Technology.
●1968 (Aug) Development of first computerized automatic exhaust gas analysis system in Japan.
●1976 (Mar) Asahi Shimbun newspaper
purchased one Titan hybrid vehicle for deliveries.
●1973 RX-3 and RX-4 automobiles with
rotary engines pass EPA tests in the United
States; certified under the Muskie Act (Clean
Air Act of 1970).
●1979 R&D begins into methanol vehicles.
●1991 (Oct) HR-X hydrogen rotary engine
concept car exhibited at Tokyo Motor Show.
HR-X hydrogen powered car
●1992 (Nov) Natural-gas engine vehicle
developed based on Capella Cargo.
●1990 (Apr) Mazda receives award from
the Director-General of the Science and
Technology Agency for research into compact, clean energy, direct injection diesel
engines.
●1998 Mazda participates in the Ford /
DaimlerChrysler / Ballard international
alliance to develop fuel-cell technology.
●1998 Heat-resistant catalyst with low-temperature performance adopted to give cleaner emissions gas.
● 1988 Slag byproduct from casting
process marketed as agent for soil improvement and asphalt foundations.
●2001 Landfill waste from plants reduced
by 70% from 1990 level.
Working towards clean manufacturing
●1970 (Apr) AGV (Auto Guided Vehicle)
system installed at plants (electric vehicles).
●1998 (Aug) Works begins on switching
head office plant heating fuel to LNG, which
has lower CO2 emissions.
●2002 (Jul) Reduction of environmental
impact from machine processing line for
new MZR engine
●2002 (Jul) Development of world's first
environmentally friendly painting technique
●1993 (Jan) Electric vehicle developed
based on Eunos Roadster.
●1994 (Mar) Road tests began on hydrogen-powered vehicle.
●1997 Diluted-burn engine adopted in all
Capella models.
36
Hydrogen rotary engine
●1981 Mazda receives Japan Society of
Mechanical Engineers Award for development of compact stable-combustion gasoline engine.
●1993 3-way catalytic system developed
for lean-burn engines.
●1975 (Jan) Waste Processing Center
begins operation at Ujina-Higashi area of
head office.
●1991 CFC recovery begins at Mazda group
service facilities.
●1973 (June) Luce AP released and designated as the first automobile eligible for tax
incentives from MITI as a Low-pollution
vehicle.
●1976 3-way catalyst system adopted,
achieving cleaner automobile exhaust emissions.
The challenge of Zero Emissions
●1997 (Dec) Demio FC-EV developed,
using fuel cell system and ultra-capacitors.
●2001 Premacy FC-EV developed and
licensed by the Transport Minister. First FCEV in Japan to begin tests on public roads.
Premacy FC-EV
Three Layer Wet paint system
Mazda's History of Environmental Activities
Energy savings
Recycling
Environmental Management / Other
●1981 (Feb) Received Chugoku Bureau of
Economy, Trade and Industry Head's award
for ductile casting continuous acid-free furnace incineration fuel savings.
●1990 Recycling Steering Committee
established.
●1992 (Apr) Mazda Global Environmental
Charter adopted.
●1991 Mazda began replacing custom
paper forms with recycled paper. Copier
paper, name cards and publicity magazines
all printed on 100% recycled paper.
●1992 (Jun) Mazda's "Action" environmental pamphlet released.
●1984 (Feb) Received the Energy Conservation Center, Japan, Director's award for
energy savings through low-frequency
induction melting furnace operation
●1985 (Feb) Received the Trade and Industry Minister's award for butane gas savings
through sintered nitrogen applications
●1987 (Nov) First large-scale cogeneration
plant in the Japanese auto industry installed
at Hiroshima head office.
electrical energy savings through the use of
high-efficiency turbo compressors
●1992 (Feb) Received the Energy Conservation Center, Japan, Director's award for energy
savings through incineration of waste products
●1993 (Jul) Hofu Plant installs first cogeneration system in world made to proprietary
Mazda design.
power savings achieved through the recovery
of low-temperature heat released from generation facilities
●1991 (Jun) Eunos Presso released, using
resin materials complying with international
standards ISO1043 and 1629 in plastic
parts.
● 1992 (Jan) Collection of damaged
bumpers begins at selected dealers in Japan.
Program expanded nationwide by the end of
1999.
●1996 (Nov) Floormats covered with fiber
made of 100% recycled PET from beverage
bottles used in Demio.
●1998 (Feb) Autonomous action plan formulated to promote recycling of end-of-life
vehicles.
Economy, Trade and Industry Head's award for the
development of a steam current observation system
●1997 (Nov) Mazda Group cooperates with
"stop engine idling" campaign to reduce
atmospheric pollution.
●1998 (Sep) Hofu Nishinoura District certified under ISO 14001.
●1999 (Apr) Aldehyde-scrubbing air filter
'Life-breath' released.
●2000 (May) AAT certified under ISO
14001.
●2001 (Feb) Damaged bumpers recovered
from the market re-used as material for
under-cover of engine area, and stripped of
coatings for use as value-added bumper
reinforcements.
Center, Japan, Superior Award for air reducing measures in construction machinery gearboxes
●2000 (Jun) AAI certified under ISO 14001.
●2000 (Jun) Entire Hiroshima Area certified
under ISO 14001.
●2000 (Jun) Mazda Telematics Center
opened.
●2000 (Oct) MECA21 formulated.
●2000 (Feb) Received MITI Minister's Prize
in the Superior Energy-Saving Application
Example category for Reduction in Air Consumption through Optimized Air Injection.
●2002 (Feb) Award of the Director of the
Energy Conservation Center, Japan received
for Energy Conservation through a Logical
Approach to Engine Plant Design.
●1993 (Jun) Environment symbol adopted to
promote environmental protection activities.
●1999 (Sep) Hofu Nakanoseki District certified under ISO 14001.
●1999 (Feb) Received the Energy Conservation
●2001 (Feb) Received the Award of the
Director of the Energy Conservation Center,
Japan, for electrical power energy savings
through measures to counter ladle heat loss
●1993 (Mar) Environment-Related Activity
Promotion Plan (Mazda Environmental Voluntary Plan) formulated.
●2000 (Apr) Uniforms for technicians and
engineers made of
fiber from recycled
PET beverage bottles.
Economy, Trade and Industry Head's award for
energy savings through low-speed shot-peening
●1997 (Feb) Mazda receives MITI (Ministry of
International Trade and Industry) Minister's Prize
in the Superior Energy-Saving Application Example category for A New Energy-Conservation
Strategy through an Energy Diagnosis System.
●1993 (Mar) Mazda Global Environmental Conference established, with Mazda president as chair.
●2001 (June) Environmental Report 2000
published on the Web.
●2001 (Sep) Environmental Report 2001
published.
Bumper reinforcement made using stripped recycled material
pallet and recycled materials
●2001 (Dec) High-strength plastics technology developed for new module carriers.
●2002 (Dec) Beginning of road tests for the
ASV advanced safety vehicle.
●2002 Received MITI Minister's Prize in the
Superior Energy-Saving Application Example category for realization of energy savings in the machine
processing line through semi-dry processing.
37
Site data
Site report: Hiroshima Area
［Head office plant］
■Address:
3-1 Shinchi, Fuchu-cho, Aki-gun, Hiroshima, Japan
■Operation started:
March 1931
■Major products:
Passenger cars, Commercial vehicles, trucks,
engines, manual transmissions for passenger cars
■Employees:
14,601 (as of end September 2002)
■ISO 14001 certification:June 2000
■Site area and floorspace:2,247,000 square meters; 1,796,000 square meters
［Miyoshi Plant］
■Address:
551-1 Higashi-sakaya-cho, Miyoshi City,
Hiroshima, Japan
May 1974
■Major product:
Engines
■Employees
157 (as of end September 2002)
■ISO 14001 certification:June 2000
■Site area and floorspace: 1,667,000 square meters; 64,000 square meters
●Environmental data for fiscal 2002
Head office Plant
Wastewater drainage to Enko River and Kaita Bay
Atmospheric pollutants
NOx
Ash
SOx
Dioxin
Units
Boilers
ppm
Drying ovens
Melting furnaces
Diesel engines
ppm
ppm
ppm
Heating furnaces
ppm
Incinerators
ppm
Boilers
g/m3N
Drying ovens
g/m3N
Melting furnaces
g/m3N
Diesel engines
g/m3N
Heating furnaces
g/m3N
Incinerators
K regulation
Waste incinerators
g/m3N
−
ng-TEQ/m3N
Regulation
300
230
150
250
180
950
200
180
150
450
0.20
0.25
0.10
0.30
0.35
0.20
0.10
0.10
0.25
0.20
0.25
7
80
Actual(max.)
182
198
77
99
107
863
117
35
52
90
0.0099
0.197
0.0028
0.0054
0.022
0.117
0.063
0.07
0.079
0.01
0.18
1.4
0.21
Water pollutants
Units
pH(freshwater)
−
pH(seawater)
−
mg/R
BOD
mg/R
COD
mg/R
SS
mg/R
Oil
mg/R
Copper
mg/R
Fluorine(freshwater)
mg/R
Fluorine(seawater)
mg/R
Zinc
mg/R
Soluble iron
mg/R
Soluble manganese
mg/R
Total nitrogen
mg/R
Total phosphorus
Coliform groups colonies/cm3
mg/R
Phenol
mg/R
Lead
mg/R
Chromium
mg/R
Boric acid(freshwater)
mg/R
Boric acid(seawater)
Ammonia, ammonium,
nitrous acid and nitrous
acid compounds
Regulation
Min.
Avg.
5.8∼8.6
5.5∼9.0
120
15
150
5
3
8
15
5
10
10
60
8
3000
5
0.1
2
10
230
7.7
7.6
4.6
12
15
1.3
0.01
0.3
6.5
1.8
0.9
0.8
42
6.2
1720
0.03
0.01
0.03
0.8
1.3
6.9
6.9
0.6
2.2
ND
ND
ND
ND
0.2
0.02
ND
ND
0.2
0.01
0
ND
ND
ND
0.3
0.1
7.2
7.2
2.3
6.1
< 4.7
< 0.6
< 0.01
< 0.2
2.1
0.31
< 0.2
< 0.3
6.3
1.3
142
< 0.02
< 0.01
< 0.01
0.5
0.8
100
4.4
1.9
3.1
mg/R
The following regulated substances were not detected: cadmium, cyanogen, organic phosphorus, hexavalent
chromium, arsenic, mercury, alkyl mercury, PCB, trichloroethylene, tetrachloroethylene, dichloromethane, carbon tetrachloride, 1.2-dichloroethane, 1.1-dichloroethylene, cis 1.2-dichloroethylene, 1.1.1-trichloroethane,
1.1.2-trichloroethane, 1.3-dichloropropene, thiuram, simazine, thiobencarb, benzene and selenium.
●PRTR (Pollution Release and Transfer Register) for fiscal 2002
(* indicates Class 1 Designated Chemical Substance of which 500 kg/year or more are handled)
(Other indications are of Class 1 Designated Chemical Substances of which 5000 kg/year or more are handled)
Head office Plant
Substance
No.
1
30
40
43
63
68
69*
179*
198
224
227
231
232*
266
299*
310
311
38
Actual
Max.
(Units: kg/year, except for dioxin which is TEQ/year)
Substance group
Water-soluble zinc compounds
Polymer of 4,4'-isopropylidenediphenol and 1-chloro-2,3-epoxypropane
Ethyl benzene
Ethylene glycol
Xylene
Chromium and trivalent chromium compounds
Hexavalent chromium compounds
Dioxins
1,3,5,7-tetraazetoricyclo [3.3.1.13.7] decane
1,3,5-trimethylbenzene
Toluene
Nickel
Nickel compounds
Phenol
Benzene
Formaldehyde
Manganese and its compounds
Amount
handled
volume emitted
Air
Water
Soil
Amount
consumed
Total
Amount Amount transferred
disposed Waste product Recycled
12,953
0
207
0
207
11,321
0
1,425
0
7,202
0
0
0
0
7,202
0
0
0
207,392
123,628
0
0
123,628
71,772
11,992
0
0
1,056,037
6
0
0
6
1,055,735
296
0
0
1,129,209
607,936
0
0
607,936
332,116
189,157
0
123,219
81,537
0
0
0
0
80,641
0
869
27
2,864
0
0
0
0
1,995
869
0
0
29.44
27
0.84
0
27.84
0
0
1.6
0
99,752
0
0
0
0
99,752
0
0
0
37,744
16,752
0
0
16.752
19,581
1,411
0
0
957,934
261,709
0
0
261,709
641,818
22,749
0
31,658
14,584
0
0
0
0
14,525
0
0
59
3,177
0
384
0
384
1,093
0
1,700
0
782,017
19
23
0
42
781,975
0
0
0
28,118
102
0
0
102
28,016
0
0
0
300,087
5,860
0
0
5,860
294,227
0
0
0
5,352
0
275
0
275
3,512
0
1,565
0
Site data
Basic environmental policy for the Hiroshima Area
The basic environmental policy in the Hiroshima Area calls for conservation of resources and energy, working toward clean business activity
in harmony with society and the local region. Concretely, our efforts are
designed to reduce environmental impact through reduction and wastes
tonnage and energy consumption, while the employees of the Hiroshima region join other Mazda Group companies in a range of environmental activities.
(Masaharu Yamaki, Managing Executive Officer and Hiroshima Plant Manager)
■Head office Plant
Miyoshi Plant
Wastewater drainage to Basen River
Units
Boilers
Diesel engines
Boilers
Diesel engines
K regulation
ppm
ppm
g/m3N
g/m3N
NOx
Ash
SOx
−
Regulation
250
950
0.30
0.10
17.5
Actual(max.)
Water pollutants
197
812
0.143
0.086
10.5
Units
pH
−
mg/R
BOD
mg/R
SS
mg/R
Oil
mg/R
Fluorine
mg/R
Zinc
mg/R
Soluble iron
mg/R
Soluble manganese
mg/R
Total nitrogen
mg/R
Total phosphorus
mg/R
Boric acid
Regulation
Actual
Max.
Min.
7.9
13
11
0.7
0.4
0.01
0.2
0.7
0.4
0.04
520
0.05
5.8∼8.6
70
70
5
8
5
10
10
60
8
3000
10
Avg.
7.3
1.3
1.2
ND
0.4
0.01
0.2
ND
0.4
0.04
0
0.05
7.6
3.8
4.9
< 0.5
0.4
0.01
0.2
< 0.4
0.4
0.04
138
0.05
The following regulated substances were not detected: cadmium, cyanogen, organic phosphorus, lead,
hexavalent chromium, arsenic, mercury, alkyl mercury, PCB, trichloroethylene, tetrachloroethylene,
dichloromethane, carbon tetrachloride, 1.2-dichloroethane, 1.1-dichloroethylene, cis 1.2-dichloroethylene,
1.1.1-trichloroethane, 1.1.2-trichloroethane, 1.3-dichloropropene, thiuram, simazine, thiobencarb, benzene,
selenium, copper, phenol, chromium, ammonia, ammonium, nitrous acid and nitrous acid compounds.
Miyoshi Plant
Substance
No.
40
63
227
299*
Substance group
Ethyl benzene
Xylene
Toluene
Benzene
Amount
handled
volume emitted
Air
Water
Soil
Total
Amount
consumed
7,505
466
0
0
466
7,039
0
0
0
34,282
1,601
0
0
1,601
32,681
0
0
0
62,761
664
0
0
664
62,097
0
0
0
2,780
10
0
0
10
2,770
0
0
0
Example of an environmental protection project
Greenbelt planting Forest areas at the Miyoshi Proving Ground
■ Japanese Cypress Trees Planted
Five Years Are Growing Well
In fiscal 1998, Mazda launched a 10-year management plan for the mountains and
forest that are part of the Miyoshi Proving Ground (Miyoshi City, Hiroshima Prefecture). During fiscal 2003 plans call for 2.8 hectares of land to be improved, with
a fiscal 2007 target of a total of 25 hectares.
This area has been identified as suffering from pine weevil damage to the red
pines in its mountain forest regions, and Mazda is implementing forest management not only to protect the wildlife of the area and preserve its natural beauty, but
also from the point of view of fire prevention.
We have cut down dead and damaged trees, and are implementing a program of
appropriate replanting of young trees in order to restore the forest landscape and
recover the flood protection offered by the forest. The 10 Year Mountain and Forest Management Plan is being implemented section by section, with the support
of the local forest cooperative.
■The Miyoshi Proving Ground
39
Site data
Site report: Hofu Plant
［Nishinoura district］
■Address:
888-1 Oaza Nishinoura, Hofu City, Yamaguchi, Japan
September 1982
■Major products:
Passenger cars
■Employees:
3,269(as of end September 2002/including Nakanoseki)
■ISO 14001 certification:September 1998
■Site area and floorspace:792,000 square meters; 297,000 square meters
［Nakanoseki district］
■Address:
415-8 Aza Ohama Ichinomasu, Oaza Hamakata,
Hofu City, Yamaguchi, Japan
December 1981
■Major product:
Transmissions
■ISO 14001 certification:September 1999
■Site area and floorspace:537,000 square meters; 100,000 square meters
[Nishinoura District]
Wastewater drainage to Oumi Bay
NOx
Units
Boilers
ppm
Drying ovens
ppm
Regulation
g/m3N
Boilers
Ash
SOx
Drying ovens
g/m3N
K regulation
−
Total regulation
Water pollutants
pH
m3N/h
Actual(max.)
150
150
250
36
230
200
0.25
0.11
0.20
0.047
0.10
< 0.001
0.35
0.024
0.30
0.027
0.20
0.0065
4.5
1.1
52.66
4.69
Actual
NOx
Ash
SOx
Regulation
−
5.0∼9.0
7.0
5.8
6.5
pH
Max.
Min.
Units
Regulation
Actual(max.)
Boilers
ppm
180
85
Boilers
g/m3N
0.30
0.027
Heating furnace
g/m3N
0.25
< 0.001
0.20
0.0098
Melting ovens
g/m3N
0.20
0.01
Ｋ
4.5
0.38
27.90
0.83
K regulation
Total regulation
Water pollutants
Avg.
Wastewater drainage to Oumi Bay
Units
m3N/h
Units
Regulation
−
5.0∼9.0
Actual
Max.
Min.
Avg.
7.9
7.5
3.3
7.7
COD
mg/R
40
14.6
3.3
9.1
COD
mg/R
40
18
SS
mg/R
30
13
0.5
1.9
SS
mg/R
30
6.9
ND
< 0.5
Oil
mg/R
2
0.7
< 0.5
Oil
mg/R
2
1.5
ND
< 0.5
Zinc
mg/R
5
0.09
0.03
0.06
Zinc
mg/R
5
0.12
0.05
Total nitrogen
mg/R
60
14
1.7
5.1
Total nitrogen
mg/R
60
14
0.9
6.2
Total phosphorus
mg/R
8
5.9
0.27
2.4
Total phosphorus
mg/R
8
0.24
0.13
0.19
148
ND
3000
280
Phenol
mg/R
5
0.09
16
Boric acid
mg/R
230
0.2
0.1
0.2
Fluorine
mg/R
15
1.1
0.98
1
Ammonia, ammonium,
acid compounds
mg/R
100
1.9
0.39
1.1
ND
< 0.05
The following regulated substances were not detected: cadmium, cyanogen, organic phosphorus, lead,
hexavalent chromium, arsenic, mercury, alkyl mercury, PCB, trichloroethylene, tetrachloroethylene,
dichloromethane, carbon tetrachloride, 1.2-dichloroethane, 1.1-dichloroethylene, cis 1.2-dichloroethylene, 1.1.1-trichloroethane, 1.1.2-trichloroethane, 1.3-dichloropropene, thiuram, simazine, thiobencarb,
benzene, selenium, chromium, copper, soluble manganese and soluble iron.
40
[Nakanoseki District]
4
10
0.09
3000
460
Boric acid
mg/R
230
0.5
ND
< 0.1
Fluorine
mg/R
15
0.1
ND
< 0.1
Ammonia, ammonium,
acid compounds
mg/R
100
5.6
3.9
232
4.8
The following regulated substances were not detected: cadmium, cyanogen, lead, hexavalent chromium,
arsenic, mercury, alkyl mercury, trichloroethylene, tetrachloroethylene, dichloromethane, carbon tetrachloride, 1.2-dichloroethane, 1.1-dichloroethylene, cis 1.2-dichloroethylene, 1.1.1-trichloroethane, 1.1.2trichloroethane, 1.3-dichloropropene, thiuram, simazine, thiobencarb, benzene, selenium, copper, soluble iron, soluble manganese, chrlmium and phenol.
Site Data
Basic environmental policy for the Hofu Plant
The basic environmental policy for the Hofu Plant calls for conservation
of resources and energy, working toward clean business activity that is
gentle on people and the global environment. While operation continues
at a high level, we are reducing the environment impact of our activities
by slashing the use of organic solvents through the world's first 3 wetcoat application painting process, and reducing energy consumption.
We will continue to work with the rest of Mazda Group in strengthening
and expanding our environmental protection activities.
(Satoshi Tachikake, Executive Officer and Hofu Plant Manager)
■Hofu Plant
[Nishinoura district]
Substance
No.
1
Substance group
Water-soluble zinc compounds
Amount
handled
volume emitted
Air
Water
Soil
Amount
consumed
Total
13,114
0
206
0
206
11,491
0
1,417
0
157,056
89,658
0
0
89,658
55,567
11,831
0
0
Ethylene glycol
1,118,220
6
0
0
6
1,118,214
0
0
0
63
Xylene
1,122,109
467,745
0
0
467,745
266,019
63,164
0
325,181
224
1,3,5-trimethylbenzene
43,001
10,999
0
0
10,999
24,079
1,286
0
6,637
227
Toluene
840,784
221,854
0
0
221,854
577,665
29,695
0
11,570
232*
Nickel compounds
2,476
0
300
0
300
852
0
1,324
0
299*
Benzene
19,571
68
0
0
68
19,511
0
0
0
40
Ethyl benzene
43
[Nakanoseki district]
None (amounts of Designated Chemical Substances defined under the PRTR Law were all below levels requiring reporting)
41
Environmental Data
Environmental Data for New Models / Redesigned Models (Passenger Cars)
*Data selected for typical version of each model
Vehicle Name
Demio
Premacy
Atenza Sedan
Atenza Sport
Atenza Sport Wagon
RX-8
Vehicle type
UA-DY3W
UA-CP8W
UAｰGGEP
UA-GGES
UA-GYEW
LA-SE3P
Model
ZJ
FP
LF
LF
LF
13B
Type
in-line DOHC 16V
in-line DOHC 16V
in-line DOHC 16V
in-line DOHC 16V
in-line DOHC 16V
2 rotor
1348
1839
1998
1998
1998
654×2
Unleaded regular
Unleaded regular
Unleaded regular
Unleaded regular
Unleaded regular
Unleaded premium
EGI
EGI
EGI
EGI
EGI
EGI
Drive system
FWD
FWD
FWD
FWD
FWD
RWD
Transmission
5MT
4AT
4AT
4AT
4AT
5MT
Vehicle weight (kg)
1060
1310
1310
1370
1370
1310
5
5（7）
5
5
5
4
17.4
13.0
14.0
14.0
14.0
10.0
○
○
○
○
○
---
Engine
Specifications
Displacement
(cc)
Fuel
Fuel supply
system
Passenger quota
Fuel
economy
Fuel efficiency at 10.15
mode (km/R)
Compliance with Japanese
2010 fuel efficiency standards
Key fuel efficiency
improvement measures
Regulations complied with
Torque converter
Torque converter
Torque converter
Torque converter
with lockup function with lockup function with lockup function with lockup function
Motorized power
steering
2000
2000
2000
2000
2000
Ultra-low emission
vehicle
Ultra-low emission
vehicle
Ultra-low emission
vehicle
Ultra-low emission
vehicle
Ultra-low emission
vehicle
Excellent-low
emission vehicle
CO (g/km) [10.15 mode]
0.67
0.67
0.67
0.67
0.67
0.67
HC (g/km) [10.15 mode]
0.02
0.02
0.02
0.02
0.02
0.04
NOx (g/km) [10.15 mode]
0.02
0.02
0.02
0.02
0.02
0.04
○
○
○
○
○
○
1998
1998
1998
1998
1998
1998
76
76
76
76
76
76
Low pollution vehicle
(local government＊)
External
noise
Variable valve timing
2000
Low Emission Vehicle
Exhaust
emissions
(As of April 2003)
Regulation complied with
Regulation value
complied with (dB-(A))
HFC-134a
HFC-134a
HFC-134a
HFC-134a
HFC-134a
HFC-134a
Greenhouse Amount of refrigerant
gases
used (g)
Air conditioner refrigerant
470
525
430
430
430
430
CO2 emissions (g/km)
136
181
168
168
168
236
Bumper and interior
Bumper and interior
Bumper and interior
Bumper and interior
Bumper and interior
Bumper and interior
materials use easily
recycled thermosetting recycled thermosetting recycled thermosetting recycled thermosetting recycled thermosetting recycled thermosetting
plastic
plastic
plastic
plastic
plastic
plastic
Parts using easily
recycled materials
Recycling
Parts using recycled PP
from bumpers, etc.
Lead usage
Splash shield
Splash shield
Footrest
Footrest
Footrest
Engine under-cover
Material marked on
plastic parts
○
○
○
○
○
○
Compared to 1996
1/3 or less
1/2 or less
1/3 or less
1/3 or less
1/3 or less
1/3 or less
＊7 metropolitan prefectures and cities, 6 prefectures and cities
●
42
See the Mazda website for data on other models, at http://www.mazda.com ●
B
Y
M
C
Note from the Editors
Mazda Motor Corporation began releasing these annual Environmental Reports in
2001, disclosing a variety of environmental information and data.
Specific content has been selected in accordance with the Environmental Reporting
Guidelines (2000 edition) on Japan issued by the Ministry of the Environment, to
explain and illustrate our environmental protection activities throughout every
phase of our business from automobile production to sale and final disposal. Toward this end, we have included key results and activities implemented jointly with
our sales firms, part and materials suppliers and logistics companies. Activities of
selected sales firms and affiliates are also covered.
New sections have been added this year to introduce the environmental protection
technologies utilized in our new Mazda6 / Atenza and Mazda2 / Demio models, released last year, as well as the adoption of production technologies with low environmental impact.
We have also expanded our coverage of Vehicle safety and workplace safety and hygiene, to facilitate better understanding of Mazda corporate activity.
Scope of this Environmental Report
［Organizations covered］
Mazda Motor Corporation, its domestic (Japanese) Group companies, and selected
Postscript
overseas Group companies.
The Mazda Environmental Report 2003 covers primarily our corpor-
［Period covered］
ate performance in environmental issues during fiscal 2002. Infor-
In principle, the fiscal year from April 2002 to March 2003, but also including selected activities from fiscal 2003.
mation and data listed is based on reports from individual internal
departments, and has been arranged for readability, based as far as
possible on concrete data.
［Contact information］
Mazda Motor Corporation PR Planning Department +81(82)282-5253 FAX +81(82)287-5225
We are continuing our environmental activities, including further in-
ISO Office (Hiroshima Region) +81(82)565-0642 FAX +81(82)287-5173
vestigation of environmental audits by third parties, and acquisition
Customer Consultation Office (toll-free)
0120-386-919
Issued by:
［Website］
Global Communications Planning Department, Mazda Motor Corporation
URL http://www.mazda.com
［Major public information releases］
Annual environmental report
of ISO14001 certification in the parts sector in summer 2003.
Annual
Environmental data for each model
Website
Company prospectus
Every six months
Press releases
As required
The next Environmental Report is scheduled to be released in fall 2004.
(Information) TEL +81(82)286-5744
FAX +81(82)287-5225
Date: September 2003
Next edition scheduled for fall 2004
Call Center
Toll-free: 0120-386-919
Hours: Monday to Friday (excluding holidays), 9:00 to 19:00
This document can also be viewed on or downloaded from Mazda's
website in PDF format.
http://www.mazda.com

mazda rx8 nitros

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